Feature

Expand into Wider Markets in Depth

1984
Aoki Works

54

November
2022

COLUMN
Cover image:

Aoki Works
1984

The office automation market, which expanded in the 1970s,
was even more robust in the 1980s. The electronics industry
was growing rapidly with many ambitious capital investments,
and production could not keep up with the increase in demand.
SANYO DENKI also put efforts to strengthen its
production capacity and newly built and opened Aoki Works
in 1984. The factory was designed to accommodate a complete
production line of stepping motors and used state-of-the-art
equipment of the time.
Aoki Works was built in response to the Aoki village's
efforts to attract companies to the area, which is locatedon the west side of Shioda-daira, also known as“Kamakuraof Shinshu”. Conveniently located about 12 km from ourthen-Ueda Works, it was a world-class, cutting-edge factoryat that time.
It is currently named Logistics Center and still plays animportant role in the company.

54
November 2022

SANYO DENKI TECHNICAL REPORT
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“Broad, Deep” Value Created Together with People

Feature: Expand into Wider Markets in Depth

Operating Officer Satoru Onodera

1

3■ Cooling Systems Division

Expand into Wider Markets in Depth

Michinori Watanabe ................................................ 3

San Ace Clean Air 9AP Type Air Purifier

Yo Muramatsu and Others ....................................... 8

40 × 40 × 20 mm and 40 × 40 × 28 mm
San Ace 40W 9WPA Type
High-Performance Splash Proof Fans Yuto Horiuchi and Others .......................................... 13■ Power Systems Division

High-Performance, High-Reliability UPSs Operable
in Various Environments Chiaki Seki ..................................................................................... 19
Development of the SANUPS A23D Online UPS

Hiroaki Miyoshi and Others .................. 24

Development of the SANUPS A11N Online UPS

Makoto Kitazawa and Others ................ 29■ Servo Systems Division

Expand into “Wider Markets in Depth”
̶ Understand customers “in depth” in “wider” applications,and develop technology and products together̶ Masahiro Yamaguchi and Others .......................... 36

Development of Compact Multi-Axis
Integrated Linear Servo Motor Unit Yuki Onda and Others ................................................... 41
Development of SANMOTION GAC Servo Systems Tsuyoshi Kobayashi and Others ......................................................................... 45

“Broad, Deep”Value Created
Together with People
Satoru Onodera Operating Ofﬁcer

Based on our corporate philosophy of “We at SANYO DENKI Group
Companies aim to help all people achieve happiness, and work with people to
make their dreams come true,” we have provided products and services that
contribute to people’s happiness.
We offer the following three product brands: San Ace for Cooling Systems
products, SANUPS for Power Systems products, and SANMOTION for Servo
Systems products. These three share a common characteristic. That is, they
are all energy converting and controlling devices. With the Cooling Systems
products, cooling fans convert electrical energy into fluid energy. With thePower Systems products, UPSs convert electrical energy into higher-quality
electrical energy. Lastly, the Servo Systems products convert electrical energy
into mechanical energy.
The value of these energy converting devices lies in the energy conversion
efficiency. Therefore, we have been committed to develop and provide ourcustomers with products that are more efficient, compact, lightweight, andlow-noise.
Conventionally, our products have been used in a relatively narrow range
of applications. For example, our cooling fans have focused on contributing to
the cooling of factory automation and ICT equipment, as well as data center
servers. Our UPSs have been used in applications that require stable power.
And the Servo Systems products have been optimally customized toeach customer for use in industrial robots, semiconductor manufacturing
equipment, machine tools, and injection molding machines. In this way, we
have been working closely with each customer to provide the most suitablecustomized products for their manufacturing applications.
However, in addition to manufacturing applications, our products are now
getting more widely used; for example, in medical equipment such as CT
scanners and in analysis equipment such as PCR testing equipment and gas
chromatographs. Recently, our linear servo motors have been used in remotecontrol systems for cell culture pipetting. We believe that our products willcontribute to wider range of applications in the future.

1

SANYO DENKI Technical Report No.54 November 2022

To achieve this, we not only need to expand the scope of target applications
and markets but also to create “new value.” The key of creating new value isco-creation where we work with all the people involved.
For example, by combining the strengths and core technologies ofcustomers and suppliers with those of our own, we will be able to create newmeaning, new significance, and new value for society.
At SANYO DENKI, we specialize in fluid technology for creating smoothwind f low, technology for cleaning and controlling power, and servo
technology for running and stopping motors as intended. We also specialize
in customization, which we have developed over many years. To deliver
optimal custom designs tailored to each customer, we need to gain a deep
understanding of our customers. Delivering optimal custom solutions to ourcustomers can be achieved by gaining a deep understanding of the issues facedby our customers, the problems they seek solutions to, and a clear image of“how they wish things to be.” We also specialize in production technology for
efficiently producing high-quality products.
By further deepening these strengths, tackling new challenges, andengaging in co-creation with all those involved, we hope our products will
make greater contributions in wider markets.
In this issue, we will be introducing our products and services that we hope
will penetrate “wider markets in depth.”
We will be introducing products and technology developed throughunderstanding and working together with our customers as well as striving to
be of benefit to people.
With these technologies, products, and services, SANYO DENKI will continue
to contribute “broadly and deeply” to the health and safety of people, preservationof the global environment, and use of new, eco-efficient energy sources.
SANYO DENKI offers energy converting devices under three productbrands of San Ace, SANUPS, and SANMOTION. We hope that these productsof ours will continue to contribute greatly in our customers’ equipment by
delivering high-quality, efficient energy.

SANYO DENKI Technical Report No.54 November 2022

2

Feature: Expand into Wider Markets in Depth

Expand into Wider Markets in Depth
Michinori Watanabe

1. Introduction

result, this equipment has become sophisticated and smaller
in size, becoming denser and generating more heat. In the

SANYO DENKI’s Cooling Systems Division has been

early days of this market, high airflow of cooling fans had

developing and offering fans chiefly for the purpose of

been in strong demand. However, as the heat generation ofcooling the inside of equipment. Starting with AC fans,equipment increased, it has become increasingly necessary

we developed brushless DC fans responding to changing

to develop “high-performance fans” featuring not only highmarket trends, and now we also offer ACDC fans, which

airflow but also high static pressure to cool equipment moreare brushless DC fans that can be powered by AC power by

efficiently. Moreover, fans with less power consumption had

internally converting AC power to DC power.

also been demanded for preserving the global environment

Conventionally, our fans have mainly been used inand lowering equipment running costs.

information and communication equipment such as inservers and ICT equipment. As this equipment has become

For example, 1U servers are the mainstream in the server

smaller in size and higher in performance, cooling fansmarket. Because of their small size, 1U (44.45 mm) servers

have been required to offer better performance—hightypically use 40 × 40 mm brushless DC fans. Today’s 1U

airflow, high static pressure, and low power consumption. In

servers are extremely dense inside and generate high heat,

response to this, we have developed new products using new

requiring fans with high airflow and high static pressuretechnology.

performance.

These products have come to be used in various fields andapplications in which fans had not previously been used.

In response, we used to meet the required performance

Also, new demands started to emerge, requiring new kinds

by using our old product developed in 1990s as a base andof fans that support recent social and environmental trends,

improving its speed by revising its drive circuit. However,which we have not offered previously.

simply increasing the fan speed was not enough to achieve

This article discusses the markets in which our coolingfans and related products have conventionally been used,
as well as potential new markets into which we expect toexpand in the future.

the required airflow performance nor was it optimal power
consumption-wise.
Fan performance is determined by (1) aerodynamic
per for ma nc e of the i mpel ler a nd f ra me, (2) motor
performance, and (3) drive circuit performance. It is

2. Our Conventional Markets
Here we introduce the conventional target markets for andthe technology used in our Cooling Systems products.

therefore important to optimize each fan component so thatthese three performance parameters are increased with theoverall balance of parameters also optimized.
To achieve higher static pressure, we formed the frame
spokes (parts securing the motor to frame) located behind

2.1 Markets for high-performance fans3

the impeller (rotor blades) into a blade-like shape (stator

Conventionally, our fans have mainly been used inblades), which proved to be effective. With 40 × 40 × 28 mm

information and com munication equipment such asaxial fans, for example, we have offered the 9GV type (2008),

in servers and ICT equipment. The popularization of

9GA type (2012), 9HV type (2015), and 9HVA type (2020)

technologies such as the Internet and mobile phones has led

with progressive improvements in performance responding

to an increase in capacity and speed of ICT equipment. As ato the market demand at the time. Figure 1 shows the

SANYO DENKI Technical Report No.54 November 2022

Expand into Wider Markets in Depthchange in product performance. Our latest 9HVA type fan

The use of such fans has been growing particularly indelivers approximately 3.3 times higher maximum airflow ofthe energy field, such as in solar power generation systems,

1.05 m 3/min and approximately 22.4 times higher maximum

storage batteries, fuel cells, fast EV chargers, and lithium-static pressure of 2300 Pa compared to our first product forion battery charge/discharge test equipment, expanding

1U servers (9P type: 109P0412H3013).

from the conventional narrow markets to wider markets.

2600
2400
2200
Static pressure [Pa]2000

109P0412H3013

1800

図版の文字

123

109P0412K3013

1600

英語版用

9GV0412K301
9GA0412P3K01
9HV0412P3K001

1400
1200
1000

Condens

英語版用

9HVA0412P3J001

800

Times Ten

600
400
200
0

0

0.2

0.4

0.6

0.8

1

1.2

Airflow [m3/min]

Inlet rotor
bladesFig. 1 Airflow vs. static pressure characteristics
of our 40 × 40 × 28 fans

StatorbladesOutlet rotor
blades

One way of achieving even higher static pressure is placing
two fans in series, but the impact of the airflow discharged by
the inlet fan with the rotor blades of the outlet fan causes agreat loss, and therefore static pressure cannot be increased
effectively. To resolve this issue, we newly developed a

Air flow direction

Counter Rotating Fan, where two fans rotating in opposite
directions to each other are combined in series. This enabled
us to significantly improve airflow characteristics. We havedeveloped and offered 40 × 40 × 56 mm Counter Rotating

Fig. 2 Structure of our 40 × 40 × 56 mm
Counter Rotating Fan

Fans: the first one is the 9CR type in 2004, and followed by a
few models, the 9CRH type in 2017 and 9CRJ type in 2020.

2.2 Markets for Splash Proof Fans

Figure 2 shows a Counter Rotating Fan and its impellers.

The first Splash Proof Fans were developed for coolingThe 9CRJ type fan delivers approximately 1.5 times higher

cellular base stations and launched in 1996. Cellular basemaximum airflow of 1.06 m 3/min, and approximately 4.7

stations are installed outdoors, and fans for cooling themtimes higher maximum static pressure of 2400 Pa comparedrequire not only cooling performance (high airflow andto the 9CR type, the first of the Counter Rotating Fan series.

high static pressure) but also environmental durability

As stated above, we have met high airflow and high static(water and temperature resistance) and long-term reliability.

pressure requirements for information and communication

In response to these requirements, we have developed aequipment such as servers and ICT equipment, contributing

series of Splash Proof Fans, which have contributed to theto the development of this equipment. In short, we havedevelopment of 3G, 4G, and 5G mobile communication

pursued higher fan performance for use in relatively limited

networks.

markets and applications, and therefore our fans have beenused in and focused on a narrow range of markets.

Our Splash Proof Fans feature IP55, IP56, or IP68rated water protection* as standard. As shown in Figure 3,
protection from water intrusion is ensured by completely

Recent years, however, the use of such high-performancecovering electrical live parts including the coil and circuit

fans featuring high airflow, high static pressure, and low

with highly water-resistant material. Moreover, components

power consumption is not limited only to the ICT equipment

exposed to outside air including the magnet and frame

market, and they are now being used in various applications

employ highly water-resistant materials, and antirust

where strong winds need to be sent in tight spaces.

treatment is done on the surface.

SANYO DENKI Technical Report No.54 November 20224

(2) Plant cultivation equipment:
Splash Proof Fans are used as continuous operability inhigh humidity environments is required.
Appropriate airflow and control of air direction are
required to circulate air uniformly inside equipment.
In this way, the application range of our Splash Proof
Fan is not limited to outdoor equipment but has been
expanding.

Fig. 3 Our Splash Proof Fan’s live parts protection* IP55/IP56/IP68 ingress protection rating
The degree of protection (IP code) is defined by IEC (International
Electrotechnical Commission) 60529 “Degrees of Protection
Provided by Enclosures (IP Code).”3. Expected Future Markets
and Required Technology
Moving forward, companies are and will be expected tooffer products and services that take environmental aspects
into consideration, and achieving carbon neutrality is now amajor challenge for the entire world.

Since around 2010, Splash Proof Fans have been adopted

The following sections will be introducing IoT-based

not only in conventional cellular base stations but also in

preventive equipment maintenance and air purifier markets,

new applications such as PV inverters, fast EV chargers,which are expected to grow in the future.

and digital signage. As with cellular base stations, thesedevices are installed outdoors and therefore require both

3.1 For achieving carbon neutrality

cooling performance and environmental durability. We

Like many countries, Japan has declared its intention

have met this demand by developing cooling fans featuring

to “achieve carbon neutrality (net-zero emissions ofhigh airflow, high static pressure, and water protection,

greenhouse gases) by 2050.”

which contributed to the environment as high-performance

To make our Cooling Systems products compliant withfans are high-efficiency energy converting devices andcarbon neutrality, we currently believe that pursuingenvironmentally friendly.

low power consumption is the most effective way to go

As described above, with water protection added to highregardless of the application. It is expected that demand

airflow and high static pressure, our Splash Proof Fans havefor low power consumption will be more and more strong

previously been employed mainly in applications for coolingin the future. For our fans, we intend to achieve evenequipment installed outdoors. They have pursued the highhigher-performance fans with lower power consumption

performance required in these limited applications, andby improving the three performance metrics mentioned intheir use has been limited to and focused on the narrowsection 2.1.

markets.

Moreover, we will help customers achieve low power

Recently, however, their use has been increasing in

consumption by expanding our fan lineup with the addition

equipment installed indoors and also for non-coolingof PWM control models enabling optimum control of

purposes as follows. The following applications use Splash

fan speed according to the amount of heat generated by

Proof Fans because exposure to water is inevitable, but as

equipment, we are helping customers reduce the amountthey are non-cooling applications, high airflow or high staticof power consumed by their equipment by expanding ourpressure is not necessarily required.

lineup of fans equipped with a speed control function using
PWM control.

(1) Food manufacturing equipment:This equipment needs to be kept clean, and fans are
exposed to water when washing it. Therefore, Splash
Proof Fans are required.

3.2 Markets for IoT-based preventive facility
maintenance
There has been a market demand for a device featuring

During a food processing using flour, fans are used

remote control and status monitoring of fans for preventive

to shake off excess flour or batter, which requires

equ ipment ma i ntena nc e a nd ef f ic ient c ool i ng a nd

appropriate airflow and control of air direction.

ventilation with various sensors combined. In response tothis, we developed and launched the San Ace Controller, an

5

SANYO DENKI Technical Report No.54 November 2022

Expand into Wider Markets in Depth

IoT-based product.
Figure 4 shows an example system configuration of the
San Ace Controller.
It enables remote control of fans for efficient cooling ofequipment, contributing to the aforementioned reduced
equipment power consumption. Moreover, measurement
data and alarm history generated during status monitoring
can be downloaded to a computer, and this data can be used
not only for equipment preventive maintenance but also
for new product development and defect analysis. This cancontribute to stable equipment operation, helping makeequipment even safer and more reliable.
Equipment
External I/O

Controller(Cloud server)

Terminal

Fig. 5 San Ace Clean Air 9AP type air purifier

FansInternet

4. Conclusion

Wireless
communication

LAN
Settings, control,and monitoring

PC

Data and alarm

DC power supply

Sensors

This article introduced past and current target markets
for our cooling fans and related products, and discussed our
expected future markets and technologies.
We h ave c o nve nt i o n a l l y fo c u s e d o n i n c r e a s i n g
the performance demanded by the information andcommunication equipment markets. In recent years,
however, the high-performance products we’ve developed
have found new opportunities in a variety of fields andFig. 4 San Ace Controller system configuration
exampleapplications: such as in the energy field, typified by solar
power generation, and for non-cooling purposes in food
manufacturing equipment.
We have also released new kinds of products leveraging

3.3 Markets for air purifiers

our specialty technology and know-how, such as IoT-based

In recent years, demand for air purifiers has been growing
in response to worsening air pollution and the spread of
COVID-19, and the market for these products has been

products for equipment preventive maintenance and the air
purifier that use our fans.
Applications for our fans have expanded from theprevious “narrow markets in depth” where we pursued

booming.
Conventionally, SANYO DENKI had had only limited

high performance in specific markets to “wider markets ininvolvement with this market by only providing fans to somedepth” by targeting a wide variety of fields leveraging our

air purifier manufacturers. However, by leveraging ourtechnical expertise, as well as new fields where demand forexpertise in fan technology and know-how in high-efficiency

fans is emerging.

air flow channel design, we made the decision to develop
and commercialize our own air purifiers for this market.
The air purifier we developed is shown in Figure 5.
This air purifier is capable of delivering high airflow of

図版

英語

Co

英語

Tim

We intend to continue identifying more new market needsfor our products and contributing to solving our customers’
problems in wider markets by developing new technologies
and new products.

16.5 m /min and cleaning a large 127 m space in only
3

2

30 minutes. Noise produced during operation is a mere
54 dB(A), and only 90 W of power is consumed.
For details, please refer to the article on this product inthis Technical Report.

SANYO DENKI Technical Report No.54 November 2022

6

Expand into Wider Markets in Depth

References(1) Hiromitsu Kuribayashi: Cooling Systems Specialty Technologies
SANYO DENKI Technical Report No. 48, pp. 3-7 (2019.11)(2) Masato Murata: Technologies Creating Change
SANYO DENKI Technical Report No. 46, pp. 3-6 (2018.11)(3) Honami Osawa: Technologies for Realizing New Dreams
SANYO DENKI Technical Report No. 50, pp. 3-7 (2020.11)(4) Toshiyuki Nakamura: Cooling Systems Technology for Protecting
PeopleSANYO DENKI Technical Report No. 52, pp. 3-5 (2021.11)

AuthorMichinori Watanabe
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

7

SANYO DENKI Technical Report No.54 November 2022

New Product Introduction

San Ace Clean Air 9AP TypeAir Purifier
Yo Muramatsu

Masahiro Koike

Soma Araki

Naoya Ozumi

Ken Fujisawa

Toshiyuki Nakamura

1. Introduction
Amid heightened awareness of measures to prevent

Tomohide Nonomura

photocatalyst for decomposing them. With HEPA filtersand photocatalyst filter, it sanitizes the air and reduces
airborne viruses, bacteria, and molds.

infection due to the spread of COVID-19, there has been

Moreover, the product has a slim profile and is equipped

growing demand for the use of air purifiers in large spaces ofwith casters, allowing it be moved around easily and be

public facilities such as hospitals and city halls where many

installed in existing facilities, despite being capable ofpeople gather.

delivering high airflow.

Conventionally, air purifiers on the market have either
been very large ones requiring installation work, orFigures 1, 2, and 3 show views of the product, and Figure 4
shows its dimensions.

compact, portable ones for household use. Both havetheir downsides: the installation of large air purifiers toexisting facilities is quite a hassle, and compact purifiers do
not offer sufficient capacity for commercial applications.
Against such a background, SANYO DENKI leveraged its
accumulated general fan expertise and high-efficiency air
flow channel design expertise to develop an easily installed,
portable San Ace Clean Air 9AP type air purifier capable ofpurifying the air in large rooms.
This article introduces the performance and features ofthis new product, as well as the key points of development.

2. Product Overview
The new product is an air purifier with low noise and highairflow that can filter, sanitize, and deodorize the air in large
rooms.
It boasts high dust removal performance using highefficiency particulate air (HEPA) filters and high airflow
thanks to its two built-in dedicated Centrifugal Fans that we
newly developed using our proprietary low noise technology.
In addition to high airflow, low noise and low power
consumption have also been achieved by employing an air
flow channel design which draws in polluted air from bothFig. 1 Appearance
San Ace Clean Air 9AP typesides of the product and discharges cleaned air from the top.
The product is also equipped with sanitization anddeodorization capabilities. Excellent deodorizing capability
has been achieved with a two-pronged approach: anactivated carbon filter for absorbing odor molecules and a

SANYO DENKI Technical Report No.54 November 2022

8

Fig. 3 Outlet duct

Fig. 2 Operating panel enlarged viewfor San Ace Clean Air 9AP type

Top

400

500

Front

Side

Rear

1600

Outlet airflow direction

Inlet airflow
direction

Fig. 4 Dimensions of San Ace Clean Air 9AP type (Unit: mm)

9

SANYO DENKI Technical Report No.54 November 2022

2600

Inlet airflow
direction

San Ace Clean Air 9AP Type Air Purifier

3. Product Features
3.1 High airflow, low noise, and low power
consumption
The product is capable of delivering high airflow of
16.5 m 3/min and thereby cleaning a large room of 127 m 2
in only 30 minutes when run in operation mode 3 (High).(1)Moreover, noise produced during operation is a mere
54 dB(A), and only 90 W of power is consumed.
To realize high airflow, an in-house developed, dedicatedlarge centrifugal fan was employed inside for circulating
air, and the product has two of these fans placed in parallel.
Furthermore, dust removal filters are installed on both sidesof the product to secure a large air inlet. Also, we designed
an efficient air flow channel for guiding air from the side

Fig. 5 Internal air flow

inlets to the top of the unit using fluid analysis simulations toachieve high airflow, low noise, and low power consumption.
Figure 5 shows the flow of air inside the product, and Figure
6 shows the fluid analysis results.
The product has a dust sensor and odor sensor inside it.

Photocatalytic unit

The automatic mode achieves even lower noise and power
consumption by detecting air contamination levels withthese two sensors and optimizing airflow from the range

Deodorizing filterof 3.2 to 16.5 m 3/min according to the contamination level
detected.

3.2 Efficient air circulation

Dust removal filter

Dust removal filter

The product employs a design that draws in contaminated
air from both sides and discharges cleaned air from theoutlet at the top. The discharged air will be dispersed along
the ceiling, providing ideal air circulation in the room.
To achieve this ideal air circulation, the outlet height andFig. 6 Fluid analysis resultslouver angle were optimized using simulations.

3.3 High dust removal performance
T he dust removal filter employs a high- efficiency
particulate absorbing (HEPA) filter. A HEPA filter iscapable of removing over 99.97% of fine particles of 0.3 μm
or larger from the air.(2) Figure 7 shows the dust removal
filter.
We secured a large filtration area by installing HEPA
filters on the left and right sides, realizing high airflow.
This large filtration area means that it takes a long time forfilters to become clogged, which increases maintainability.
The product is also equipped with a sensor for detecting theclogging in filters.

Fig. 7 Dust removal filter (pre-filter + HEPA filter)

SANYO DENKI Technical Report No.54 November 2022

10

3.4 Deodorization and sanitization
In addition to HEPA filters, the product also has anactivated carbon filter for absorbing and deodorizing odor

4. Specifications
Table 1 shows the specifications of the product.

particles. Figure 8 shows the deodorizing filter.
The activated carbon filter is capable of reducing a highTable 1 Specifications of the new productconcentration of odor, such as cigarette smoke, by half in

Suitable airflow can be selected from four operation modes:
1 [Low], 2 [Medium], 3 [High], and [Auto].

30 minutes. .
(1)Model no.

9AP1600-1

Dimensions[mm]

500 (W) × 400 (D) × 1600 (H)Mass [kg]40Power supply

Single-phase 100 V (50/60 Hz supported)

the air drawn into the air purifier. Figure 9 shows aPower cord
length [m]2.6

photocatalytic unit.

Room coverage Up to 127 m2*

Also, the product has a photocatalytic filter. With thesurface of the photocatalytic filter irradiated by ultraviolet
light, the photocatalytic coating on the filter surface getsoxidized, which decomposes contaminants like bacteria
and viruses into CO2 and water, sanitizing and deodorizing

Combination use of the HEPA filters and photocatalytic
unit ensures the removal of over 99% of contaminants suchas bacteria and viruses.(3)Fig. 8 Deodorizing filter (activated carbon filter)* Calculated by the test method based on the JEMA’s JEM 1467
standard.

Operation
mode

1
[Low]

2
[Medium]

3[High]

Airflow[m3/min]

3.2

10.5

16.5

Power
consumption
[W]

18

28

90

Noise level[dB(A)]

30

45

54

SensorDust, odor

Dust removal

HEPA filter

Sanitization,
deodorization

Photocatalytic filter, deodorizing (activated carbon)
filterFunctionsAuto-off timer (3/6/12 hours), key lock function(disables all buttons except the power off toprevent accidental button presses)

Auto

Built-in sensors
detect dust and odors
to automaticallyselect the optimal
operation mode.

4.1 Operation modes
The product features 3-speed operation modes, which
deliver airflow in Low, Medium, and High levels, andPhotocatalytic filter

Photocatalytic filter

an automatic operation mode linked to internal sensors.
The airflow levels can be set in a wide range from 3.2 to
16.5 m 3/min, and the Low operation mode runs quietly with
only 30 dB(A) noise.

5. Conclusion
T h is a r ticle i ntroduced some of the featu res a nd
performance of the San Ace Clean Air 9AP type air purifier
for commercial use.
Ultraviolet lights

Incorporating SA N YO DEN K I’s accumulated fan
technology and new technology has made it possible toFig. 9 Photocatalytic unit
(photocatalytic filters + ultraviolet lamps)

develop the high-airflow air purifier capable of cleaning the
air in large rooms. Against the background of increasing
air pollution and the spread of COVID-19, we believe that11

SANYO DENKI Technical Report No.54 November 2022

San Ace Clean Air 9AP Type Air Purifier

this product can contribute greatly to society’s demand for

Authorclean air.
We will continue to help our customers create newvalue by providing products that promptly address market
demand.
(1) Calculated by the test method based on the Japan Electrical
Manufacturers’ Association (JEMA) standard, JEM 1467.
(2) This is the filtration performance of the filter and not about thefiltration of the entire room.
(3) This effect was confirmed in a closed test space of 25 m3 as
per JEMA’s JEM 1467 standard and not in actual practice.

Yo Muramatsu
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Masahiro Koike
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Soma Araki
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Tomohide Nonomura
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Naoya Ozumi
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Ken Fujisawa
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Toshiyuki Nakamura
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

SANYO DENKI Technical Report No.54 November 2022

12

New Product Introduction

40 × 40 × 20 mm and 40 × 40 × 28 mm
San Ace 40W 9WPA Type
High-Performance Splash Proof Fans
Yuto Horiuchi

Koji Ueno

Yukihiro Nagatsuka

Kenya Horiuchi

Sho Matsushita

Hiromitsu Kuribayashi

Masaki Kodama

1. Introduction
In recent years, outdoor equipment such as base stations,quick EV chargers, and surveillance cameras is becoming
more compact and sophisticated in design and increasing indensity, generating more heat. This has raised demand forcompact splash proof fans with better performance.
Previously, SANYO DENKI has proposed its compact
splash proof fans—40 × 40 × 20 mm 9WP type and 40 ×
40 × 28 mm 9WL type Splash Proof Fans—but nowadays
increasingly more cases are requiring higher performance.
In response to this demand, we newly developed andlaunched a San Ace 40W 9WPA type Splash Proof Fan in 40
× 40 × 20 mm and 40 × 40 × 28 mm sizes (hereinafter, new
20 mm thick models and 28 mm thick models) offering theindustry’s highest(1) airflow and static pressure.

Fig. 1 40 × 40 × 20 mm San Ace 40W 9WPA typeThis article introduces the features and performance of
these new models.
(1) Based on our own research as of June 28, 2022, conductedamong equally-sized splash proof fans on the market.

2. Product Features
The new 20 mm and 28 mm thick models are compatible
in frame size and mounting with our current 40 × 40 ×
20 mm San Ace 40W 9WP type and 40 × 40 × 28 mm San
Ace 40W 9WL type fans, respectively, while achieving
higher airflow, higher static pressure, and lower power
consumption.
Figures 1 and 2 show the new models.

Fig. 2 40 × 40 × 28 mm San Ace 40W 9WPA type

13

SANYO DENKI Technical Report No.54 November 2022

40 × 40 × 20 mm and 40 × 40 × 28 mm San Ace 40W 9WPA Type High-Performance Splash Proof Fans

3. Product Overview

The new models’ structural features are as follows.
(1) Electrical live parts (windings and circuits) are coatedwith highly water-resistant material. Figure 3 shows how

3.1 Dimensions
Figures 4 and 5 show the dimensions of the new models.

it looks.
(2) E a c h pa i r of t he new a nd c u r rent mo d el s h a s

3.2 Characteristics

compatibility in frame size and mounting, and the newTable 1 to 4 shows the specifications of the productmodels use a highly environmental durability resin

and Figures 6 to 13 show the airflow vs. static pressurematerial in the frame and blades.

characteristics of the new models.
Rated voltages of 12 V and 24 V are available to support
operation in a wide range of applications. The new models
are available in high-speed (G speed) and low-speed (Hspeed) models.
The G-speed models have a PWM control function. Thisfunction controls fan speed according to the heat generationi nside equ ipment to keep the cool i ng per for ma nce
optimized at all times, enabling low power consumption andlow noise.
The new models have an expected life of 40,000 hours at
60°C (survival rate of 90%, run continuously at rated voltage

Fig. 3 Coating of electrical live parts(New 28 mm thick model)

and normal humidity in free air).

40±0.320±0.54×ø3.5±0.3

（4）

（4）

32±0.332±0.340±0.332±0.3（10）40±0.3+30
320 0

SANYO DENKI

Rotational direction

Airflow direction

Fig. 4 Dimensions of 40 × 40 × 20 mm San Ace 40W 9WPA type (Unit: mm)

4×ø3.5±0.3（4）40±0.328±0.5（4）32±0.3

+30
320 0
（10）
SANYO DENKI

Rotational direction

Airflow direction

Fig. 5 Dimensions of 40 × 40 × 28 mm San Ace 40W 9WPA type (Unit: mm)

SANYO DENKI Technical Report No.54 November 2022

14

Table 1 General specifications of 40 × 40 × 20 mm San Ace 40W 9WPA type high-speed model
Operating
Rated
PWM
Rated Rated
voltagevoltageduty cycle* current input
range
[V]
[%]
[A]
[W]
[V]
100
0.17 2.0
10.8 to
9WPA0412P6G001
12
13.2
25
0.03 0.36
100
0.09 2.0
21.6 to
9WPA0424P6G001
24
26.4
25
0.03 0.72
Model no.

Sound Operatingpressure temperature Expected life
level
range
[h]
[Pa] [inchH2O][dB(A)]
[°C]
210
0.84
44
40000
9.8 0.04
12
at 60°C-20 to +70(70000210
0.84
44
at 40˚C)
15
0.06
14
Max.
static pressure

Rated
speed
[min-1][m3/min] [CFM]

13700
3000
13700
3600

0.38
0.07
0.38
0.09

Max. airflow

13.4
2.5
13.4
3.2

* Input PWM frequency: 25 kHz. Speed is 0 min -1 at 0% PWM duty cycle.

Table 2 General specifications of 40 × 40 × 20 mm San Ace 40W 9WPA type low-speed model
Rated Operating Rated Rated Rated Max. airflow
voltage voltage range current input speed
[V]
[V]
[A]
[W] [min-1] [m3/min] [CFM]

Model no.
9WPA0412H6001
9WPA0424H6001

12
24

7 to 13.8
14 to 27.6

0.075
0.038

0.9

8800

0.24

Max.
Sound
Operatingstatic pressure pressure level temperature range[Pa] [inchH2O][dB(A)][°C]

Expected life[h]8140000 at 60°C
(70000 at 40˚C)

8.5

0.33

34

-20 to +70

Table 3 General specifications of 40 × 40 × 28mm San Ace 40W 9WPA type high-speed model
Operating
Rated
PWM
Rated Rated
voltage
Model no.
voltageduty cycle* current input
range
[V]
[%]
[A]
[W]
[V]
100
0.50 6.0
10.8 to
9WPA0412P3G001
12
13.2
20
0.06 0.72
100
0.25 6.0
21.6 to
9WPA0424P3G001
24
26.4
20
0.06 1.44

Sound Operatingpressure temperature Expected life
level
range
[h]
[Pa] [inchH2O][dB(A)]
[°C]
555
2.22
53
40000 at28.1 0.11
21
60°C-20 to +70(70000555
2.22
53
at 40˚C)
95
0.38
34
Max.
static pressure

Rated
speed
[min-1][m3/min] [CFM]

22200
5000
22200
9200

0.63
0.14
0.63
0.26

Max. airflow

22.2
4.9
22.2
9.1

* Input PWM frequency: 25 kHz. Speed is 0 min -1 at 0% PWM duty cycle.

Table 4 General specifications of 40 × 40 × 28 mm San Ace 40W 9WPA type low-speed model
Rated Operating Rated Rated Rated Max. airflow
voltage voltage range current input speed
[V]
[V]
[A]
[W] [min-1] [m3/min] [CFM]

Model no.
9WPA0412H3001
9WPA0424H3001

12
24

7 to 13.8
14 to 27.6

1.0

250

0.8

200

0.6

100

0.2

50

0

18500

0.52

375

40000 at 60°C
(70000 at 40˚C)

1.51

1.0

PWM duty cycle
100%

PWM duty cycle
25%

0.1

0
2

4

0.2
6

0.3

0.4

8 10 12 14 16
Airflow48-20 to +70

24 VDC250

PWM duty cycle
100%

0.8 200

PWM duty cycle
50%

00.5［m3/min］［CFM］

Fig. 6 Airflow vs. static pressure characteristics
of 40 × 40 × 20 mm San Ace 40W 9WPA type 12 V,
high-speed model
15

18.3

［inchH2O］［Pa］

12 VDC

150

0.4

4.1

Expected life[h]Static pressure

Static pressure［inchH2O］［Pa］

0.34
0.17

Max.
Sound
Operatingstatic pressure pressure level temperature range[Pa] [inchH2O][dB(A)][°C]

SANYO DENKI Technical Report No.54 November 2022

0.6

150

0.4

100

0.2

50

0

PWM duty cycle
50%
PWM duty cycle
25%

0.1

0
0

2

4

0.2
6

0.3

0.4

8 10 12 14 16
Airflow

0.5［m3/min］［CFM］

Fig. 7 Airflow vs. static pressure characteristics
of 40 × 40 × 20 mm San Ace 40W 9WPA type 24 V,
high-speed model40 × 40 × 20 mm and 40 × 40 × 28 mm San Ace 40W 9WPA Type High-Performance Splash Proof Fans［inchH2O］［Pa］［inchH2O］［Pa］

0.5

0.5

140

140

120

0.3

0.4

13.8 V

Static pressure

Static pressure

0.4 100
80

12 V
60

0.2

0.3

7V

20
0
2

4
6
Airflow

10 ［CFM］

8［inchH2O］［Pa］

12 VDC

7000

PWM duty cycle
50%

300

PWM duty cycle
20%

1.5

PWM duty cycle
50%

400

PWM duty cycle
20%

300

0

0.1 0.2 0.3 0.4 0.5 0.6 0.7［m3/min］

0

5

10
15
Airflow

20

5

10
15
Airflow20

25 ［CFM］

Fig. 11 Airflow vs. static pressure characteristics
of 40 × 40 × 28 mm San Ace 40W 9WPA type 24 V,
high-speed model［inchH2O］［Pa］

2.0 500

1.5
Static pressure

13.8 V
300
1.0

12 V
200

0.1

0.2
5

0.3

0.4

10
15
Airflow

0.5

0.6［m3/min］
20 ［CFM］

Fig. 12 Airflow vs. static pressure characteristics
of 40 × 40 × 28 mm San Ace 40W 9WPA type 12 V,
low-speed model

400
27.6 V
300

1.0

24 V
200

0.5

7V

100

0

0.1 0.2 0.3 0.4 0.5 0.6 0.7［m3/min］

0
0

400

0

100

25 ［CFM］

2.0 500

Static pressure

PWM duty cycle
100%

1.0

0.5

100

［inchH2O］［Pa］

0

600

200

Fig. 10 Airflow vs. static pressure characteristics
of 40 × 40 × 28 mm San Ace 40W 9WPA type 12 V,
high-speed model

0.5

10 ［CFM］

8

24 VDC

2.0 500400

0.3［m3/min］

0.2

4
6
Airflow

700

PWM duty cycle
100%

0

1.5

0.1
2

［inchH2O］［Pa］

200
0.5

0

Fig. 9 Airflow vs. static pressure characteristics
of 40 × 40 × 20 mm San Ace 40W 9WPA type 24 V,
low-speed model

2.5

1.0

14 V

20

0

600

2.0 500
Static pressure00.3［m3/min］

0.2

Fig. 8 Airflow vs. static pressure characteristics
of 40 × 40 × 20 mm San Ace 40W 9WPA type 12 V,
low-speed model

1.5

24 V

0.2

0.1

0.1
0

2.5

27.6 V

80

40

Static pressure

0

100

60

40
0.1

120

0

14 V
100

0
0

0.1

0.2
5

0.3

0.4

10
15
Airflow

0.5

0.6［m3/min］
20 ［CFM］

Fig. 13 Airflow vs. static pressure characteristics
of 40 × 40 × 28 mm San Ace 40W 9WPA type 24 V,
low-speed model
SANYO DENKI Technical Report No.54 November 2022

16

4. Comparison of New and Current
Models12 VDC, PWM duty cycle 100%250

4.1 Comparison of airflow vs. static pressure
characteristics

New model
9WPA0412P6G001
Speed: 13700 [min-1]
Power consumption: 2.0 [W]200

Figures 14 and 15 show a comparison of airflow vs. staticpressure characteristics for the new and current models.
thick model achieves 69% higher maximum airflow and
220% higher maximum static pressure.
C ompared to the current 9WL type model, the new
28 mm thick model achieves higher static pressure acrossall operating ranges and 38% higher maximum static

Static pressure [Pa]Compared to the current 9WP type model, the new 20 mm
150
Current model
9WP0412H6001
Speed: 8000 [min-1]
Power consumption: 1.2 [W]220%
increase100

pressure.

5. Key Points of Development

50

The new models use a high-efficiency motor for faster69%
increase

speed, and frame and blades are newly designed and thereby
achieve significantly higher airflow, higher static pressure,0

and lower power consumption than the current models.

0

0.1

0.2

0.3

0.4

0.5

Airflow [m3/min]

The new models also feature high IP68-rated water andFig. 14 Comparison of new 40 × 40 × 20 mm
San Ace 40W 9WPA type with current model

dust protection.(2) From the early phase of development,
the design team put an effort in making manufacturing
productivity as high as possible in addition to improving fan
performance and reliability.
The key points of development are described below.
(2) IP68 ingress protection rating
The degree of protection (IP code) is defined by IEC(International Electrotechnical Commission) 60529 “Degrees
of Protection Provided by Enclosures (IP Code).”600

5.1 Structural design500

shape was designed to deliver faster speed.
The fan blades were made strong enough for faster
speeds and designed to achieve high airflow and high staticpressure.

Static pressure [Pa]T he resi n mater ia l most su itable for the productspecifications was selected for the frame, and the frame

12 VDC, PWM duty cycle 100%

700

New model
9WPA0412P3G001
Speed: 22200 [min-1]
Power consumption: 6.0 [W]38%
increase

Current model
9WL0412P3J001
Speed: 17500 [min-1]
Power consumption: 6.24 [W]

400

300

To achieve water and dust protection, all electrical live
parts were covered with a highly water-resistant resin

200

coating. Moreover, both reliability and productivity
were secured by devising the optimal coating shape andthickness.

5.2 Motor and circuit
By opti m i zing the motor and its dr ive system forindividual voltages and speeds, we successfully developed
a high-efficiency motor with reduced heat generation fromthe motor and its circuit. As a result, the new 20 mm and

17

SANYO DENKI Technical Report No.54 November 2022

100

0

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Airflow [m3/min]Fig. 15 Comparison of new 40 × 40 × 28 mm
San Ace 40W 9WPA type with current model40 × 40 × 20 mm and 40 × 40 × 28 mm San Ace 40W 9WPA Type High-Performance Splash Proof Fans

28 mm thick models are 1.5 times and 1.3 times faster thanand lower power consumption. With these features, wethe current models, respectively, and both achieve reduced

believe that the new models will greatly contribute to

power consumption.

outdoor equipment such as base stations, quick EV chargers,

As an example, Figure 16 provides a comparison of
power consumption for new and current 40 × 40 × 20 mm

and surveillance cameras which requires higher cooling
performance and energy efficiency than ever before.

models at equivalent cooling performance. Compared to

We will continue developing products in response to

the current model, the new model boasts 37% lower power

various market needs. In particular, we plan to continue

consumption.

offering products in a timely manner which contribute to theAlso, compared to the current model, the new model
offers higher static pressure and consumes less power acrosscreation of new value for our customers to help make their
dreams come true.

all operating ranges.
12 VDC150

120(3) Based on our own research as of June 28, 2022, conductedamong equally-sized water-resistant fans on the market.

1.5

Author

1.2

Yuto Horiuchi

90

0.9

60

0.6

Power
consumption

Power consumption [W]Static pressure [Pa]37%
reduction

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Design Department, SANYO DENKI TAIWAN CO. LTD.
Works on the development and design of cooling fans.

30

0.3
Estimated
operatingpoint

0

Koji Ueno

Yukihiro Nagatsuka

Staticpressure0

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

0.1

0.2

Masaki Kodama
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

0

Airflow [m3/min]Current model 9WP0412H6001
New model (PWM duty cycle 53%) 9WPA0412P6G001
System impedance

Kenya Horiuchi
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Sho Matsushita
Fig. 16 Comparison of new 40 × 40 × 20 mm
San Ace 40W 9WPA type with current modelat equivalent performance

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Hiromitsu Kuribayashi

6. Conclusion

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

This article introduced the features and performance ofthe 40 × 40 × 20 mm and 40 × 40 × 28 mm San Ace 40W
9WPA type high-performance Splash Proof Fans offering
the industry’s highest(3) airflow and static pressure.
Compared with the current models, the new models
achieve remarkably higher airflow, higher static pressure,

SANYO DENKI Technical Report No.54 November 2022

18

Feature: Expand into Wider Markets in Depth

High-Performance,
High-Reliability UPSs Operable
in Various Environments
Chiaki Seki

1. Markets Where UPS is Needed

and countries where grid power is unstable. Even in Japan,
the voltage at the end of a power system within the same

Use of an uninterruptible power supply (hereinafter,

building may become unstable due to the operation of“UPS”) had once been limited to special applications

various equipment. In summary, UPSs are required to keep

but has now become common. Nowadays, for example,

running on grid power in a wider voltage range.

telecommunications equipment, factory equipment, store
equipment, and office equipment, and they are used in many
countries. Therefore, UPSs today are required to operatesafely even with variations in environmental and power
supply conditions.
Also, market demand for more efficient power supply
equipment has been increasing in response to increasing
initiatives for achieving carbon neutrality by 2050.
Besides, customers focus on the role of a UPS of supplying
continuous power efficiently, and they expect UPSs withhigh added value features such as long life, high efficiency,
high reliability, and ease of maintenance.
SANYO DENKI’s Power Systems Division has beendeveloping and offering UPSs up to customer satisfaction

Input voltage range for grid operation [%]UPSs are used in a wide variety of applications such as
60
50
40
30
20
10
0
-10
-20
-30
-40
-50
-60
-30

Current environmental range

Conventional
environmental range

-20

-10

0

10

20

30

40

50

60

Operating temperature range [°C]
Note 1: The range extension varies by product.
Note 2: Each product has its own operating conditions and restrictions.

Fig. 1 Change of UPS installation environments

by supporting various installation and power supply
env i ron ment s a nd i mprov i ng f u nct iona l it y a nd
performance. This article introduces some of our UPSs
in the following sections.

2. Demand for UPSs Supporting
Various Operating Environments

O n t he ot her h a nd , we mu st f u r t her re duc e t heenvironmental impact of our products to preserve the global
environment and achieve carbon-neutral society. The same

As stated above and also shown in Figure 1, UPSs are now

goes for UPSs and other power supply equipment, andrequired to support a wider range of installation and power

customer requirements won’t be met unless we continue tosupply environments.

deliver even higher efficiency and longer service life.

UPSs were previously used in limited locations where theBesides, a UPS system must be highly reliable, scalable,temperature was controlled, but recently, they have been

and maintainable to ensure a continuous power supply,

installed in environments with insufficient temperature

which is the primary role of a UPS. In addition, customers

control or poor power quality. Moving forward, UPSs musthave demanded less maintenance so that they can focus on

therefore operate stably in an environment with a wider

providing their own service without being distracted, whichrange of temperatures.

can be achieved by using LIB (lithium-ion battery). Figure 2

Regarding the power supply conditions, there are regions

19

3. Functionality, Performance,
and Reliability Required of UPS

SANYO DENKI Technical Report No.54 November 2022shows major UPS features required by customers.

High-Performance, High-Reliability UPSs Operable in Various Environments

Reduced running costs

High efficiency

Reduced environmental impact

Parallel redundant system

High reliability

Repair-friendly design

High functionality, performance,and reliability requirements
Maintainability and scalability

Easily scalable capacity
Reduced maintenance costs

Long life

No need for battery replacement
Reduced weight in regular replacement parts

Fig. 2 Functionality, performance, and reliability required of UPS

4. SANUPS A11K-Li and E11B-Li

T he SA NUPS A 11K-Li features a wide operating
temperature range and can be used at temperatures of -20 to

The UPSs shown in Figures 3 and 4, in addition to+55°C. The UPS tolerates -40% to +20% deviations from the

supporting a wider range of operating and power supply

rated input voltage, and the frequency tolerance canbe set by
図版の文字

environments, offer high efficiency and LIB advantages ofusers between ±1% and 7% of the rated input frequency.

123

英語版用

longer life and lower running and maintenance costs.
The SANUPS A11K-Li is a double conversion online UPS
that can supply high-quality power. This UPS has single-

Condens

In addition, the LIB enables long-term backup英語版用
while also
reducing size and weight.

Times Tenphase 100 V input/output voltage, and its lineup is available

The SANUPS E11B-Li is a hybrid UPS. The lineup isin output capacities of 1, 1.5, 2, 3, and 5 kVA. It is suitableavailable in single-phase input/output voltages of 100 andfor power backup of computers and servers.

200 V and output capacities of 1, 1.5,(1) and 2 kVA, making ita highly versatile UPS that can be used worldwide.
Its hybrid topology features two operation modes: Double
Conversion mode offering high-quality power and Economy
mode offering high efficiency, which can be set by users
according to the operating environment.
When the setting is fixed to Double Conversion mode,
the inverter always supplies high-quality power. During
Automatic setting, the UPS switches automatically between
Double Conversion mode and Economy mode dependingon the state of the input power, achieving both high-quality

Fig. 3 SANUPS A11K-Li 1.5 kVA model

power and high efficiency.
The SA NUPS E11B -Li features a wider operating
temperature range and can operate safely at temperaturesof -10 to +55°C. For example, this UPS can be used in
extremely hot or cold regions and in buildings without airconditioning. As for power conditions, the UPS tolerates awide input voltage range of 55 to 150 V (100 V models) or
110 to 300 V (200 V models) and a wide input frequency
range of 40 to 120 Hz. These wide ranges reduce the number

Fig. 4 SANUPS E11B-Li 1 kVA modelof transfers to battery operation and battery wear, supplying
stable power to the load even in regions where grid power isunstable and voltage and frequency fluctuate greatly.

SANYO DENKI Technical Report No.54 November 2022

20

U P S s u s i n g le a d - a c id b at t er ie s re qu i re b at t er yreplacement every 5 years, but both SANUPS A11K-Li
and SANUPS E11B-Li use LIBs, which have an expectedbattery life of approximately 10 years. As the expected lifeof the UPS unit is also 10 years, maintenance work such asbattery replacement will not be required during its service
life, reducing maintenance costs for customers.
(1) 1.5 kVA model is available for 100 V only.

5. SANUPS A11N, A11M, and A11M-Li
The UPSs shown in Figures 5 to 7 cover a wide rangeof temperature and power conditions and features highefficiency, capacity scalability by combining multiple units,

Fig. 5 SANUPS A11N 5 kVA model, single-unit type(mounted in a rack)high reliability with parallel redundant operation, and highmaintainability with easy addition and replacement of units.
The SANUPS A11N is available in two types: a single
unit type that has a single 5 kVA base unit with AC output
outlets on the back of the unit or a parallel connection typethat comes with a power distribution unit and is scalable up
to 20 kVA by combining up to four base units in parallel.
The input/output voltage can be set to single-phase 200,
208, 220, 230, or 240 V, making this UPS suitable for use not
only in Japan but also in global markets.
Moreover, by using a power distribution unit with atransformer, it can also connect to single-phase 100 V
systems or single-phase 3-wire systems.
At full load level, the UPS tolerates input voltage ranging
from -20% to +15% of the rated voltage. At low load levels,
the UPS can handle a wider -40% to +15% range of input

Fig. 6 SANUPS A11N 20 kVA model,
parallel connection typevoltage and maintain power supply without switching tobattery operation. In addition, by setting to Fixed Frequency
mode, the UPS tolerates input frequency ranging from 40 to
120 Hz and supplies 50/60 Hz out power. These wide input
voltage and frequency ranges allow the product to be usedeven in regions with unstable power supply.
Also, when Fixed Frequency mode is selected, theasynchronous startup allows power to be supplied withan output frequency of 50/60 Hz regardless of the local
frequency.
The SANUPS A11M/A11M-Li, developed based on
our SANUPS E11B/E11B-Li and featuring the double
conversion online topology, offer scalable capacity andparallel redundant operation by combining multiple units.
By combining 1 kVA UPS units in parallel, the output
capacity can be scalable up to 8 kVA.
Maintaining the SANUPS E11B/E11B-Li’s support for
wide-ranging operating and power conditions, they can beused with peace of mind in a wide range of temperatures.

21

SANYO DENKI Technical Report No.54 November 2022

Fig. 7 SANUPS A11M 8 kVA model(mounted in a rack)

High-Performance, High-Reliability UPSs Operable in Various Environments

They can be used with little transfer to battery power andto -30%, making it ideal for power backup in buildings withminimal battery wear even in regions where grid power

relatively large power supply fluctuations.

supply is unstable and voltage and frequency change

The SANUPS A23D has also improved the rectifier anddrastically while supplying stable, high-quality power to theinverter control to reduce switching losses and increaseload thanks to the double conversion online topology.

efficiency, achieving higher conversion efficiency over theAlso, like the SANUPS E11B-Li, the SANUPS A11M-Li

predecessor.

uses LIBs, which eliminate the need for battery replacement

This has resulted in an industry-leading (2) conversion

during the product’s expected life of 10 years, reducing

efficiency of over 94% (up to 95.6%), which suppresses power

maintenance work and costs for customers.

consumption and heat generation, reducing running costs and

The SANUPS A11N and SANUPS A11M /A11M-Li

CO2 emissions.

all use “fully autonomous control” for parallel operation

The SANUPS A23D comes with a new “walk-in feature”

control, which synchronizes each unit’s voltage amplitude,

as standard. Some applications where an uninterrupted, long-phase, and frequency as well as controls the cross current

term power supply is needed in the event of a power failure

and load sharing between units. This makes it possible

require an emergency power supply system combining an

to disconnect only the failed units during the parallel

emergency generator with a UPS. With this system, power isredundant operation as shown in Figure 8, providing afirst supplied from batteries when grid power fails, meanwhile,highly reliable power supply as well as easy expansion and

the AC input of the UPS switches from the grid power to thereplacement of units.

generator output. After that, the generator will power theconnected facilities via the UPS.
If there is a sudden increase in the UPS’s AC input during

Unit No. 1

the switchover to the generator, the generator output voltage

Unit No. 2

will fluctuate. If this fluctuation is large, the UPS will detect

Failurethe fluctuation low, a generator with extra capacity would

an AC input error and transfer back to battery power. To keep
be required. The walk-in feature provides a solution for thisby ensuring that the UPS gradually receives power from the（N+1）kVA

Unit No.（N）Unit No.（N+1）

Power supply canbe maintained
if the load is N kVA or lessgenerator. This function reduces output voltage fluctuationsof the generator during power restoration, allowing customers
to build economic emergency power supply systems by not
requiring extra capacity of a generator.

Maintenance bypass
Power distribution unit

Fig. 8 Parallel redundant systemwith SANUPS A11N, A11M(-Li)

6. SANUPS A23D
This product is shown in Figure 9 and supports a wide rangeof power supply environments, offers high efficiency, and helps

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123

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minimize running and maintenance costs by using less regularCondens

replacement parts.

英語版用

The SANUPS A23D, the successor to our SANUPS A23C

Times Tendouble conversion online UPS, supports 3-phase 3-wire
200 V systems and offers higher efficiency and functionality.
The lineup is available in output capacities of 30, 50, 75, and100 kVA. The input voltage range is normally 200 V ±15%
for 200 V output, but if the load level is 60% or less, the UPS
can support an extended range with the lower limit changed

Fig. 9 SANUPS A23D 100 kVA model

SANYO DENKI Technical Report No.54 November 2022

22

High-Performance, High-Reliability UPSs Operable in Various Environments

The expected product life is the same 15 years as the

Authorcurrent product, during which some parts need to be replaced
periodically. By reviewing the parts selection and improving

Chiaki Seki

efficiency, the electrolytic capacitors and cooling fans, which

Design Dept., Power Systems Div.
Works on the development, design, and quality control of power
supplies.

are the main replacement parts, do not need to be replacedfor 15 years. This reduces replacement time and costs, thereby
reducing maintenance work and costs for customers.
(2) Based on our own research as of March 10, 2022, conductedamong UPSs on the market with the same topology andequivalent voltage, capacity, and backup time.

7. Conclusion
SANYO DENKI will continue to offer power supply
equipment such as UPS that can be used safely even in harshenvironments to meet customer expectations and contributeto a low-carbon society.
In addition, we will endeavor to develop new technologies
to introduce higher quality power supplies into new fields
that require operations in unusually severe environments.
References(1) Yuhei Shoyama and 11 others: Development of the Small-Capacity
UPS SANUPS A11K-Li and SANUPS N11B-Li Series
SANYODENKI Technical Report No. 44, pp. 25-33 (2017.11)(2) Hiroyuki Hanaoka and 6 others: Development of the SANUPS
A11M Small-Capacity UPSs
SANYODENKI Technical Report No. 48, pp. 22-27 (2019.11)(3) Akihiro Tsukada and 7 others: Development of the SANUPS E11B
Hybrid UPS
SANYODENKI Technical Report No. 51, pp. 22-26 (2021.5)(4) Hiroshi Sakaba and 7 others: Development of Compact UPS Series
SANUPS E11B-Li and SANUPS A11M-Li
SANYODENKI Technical Report No. 52, pp. 24-30 (2021.11)

23

SANYO DENKI Technical Report No.54 November 2022

New Product Introduction

Development of the SANUPS A23D
Online UPS
Hiroaki Miyoshi

Yuji Wada

Naoya Nakamura

Satoshi Furihata

Takuya Ota

Shohei Ohashi

Minoru Yanagisawa

Mika Takehara

1. Introduction
The growth of the information society has led to anincrease in various information and ICT equipment such

Katsutoshi Tanahashi

power is always supplied through the inverter. In the event ofa power outage, it doesn’t need to switch power sources andprovides an uninterrupted power supply without causing
voltage fluctuations.

as servers for data centers, and outages of such equipment

This UPS also features bypass startup where power is

can have a significant impact on society. An uninterruptible

supplied from the bypass circuit when the inverter stops,

power supply (hereinafter, “UPS”) has become essential aswhich reduces the possibility of system downtime even if thea backup power source for such equipment. In recent years,

product fails and its inverter stops.

with the shift to smart factories, measurement data obtained
from IoT and sensors has been leveraged more and more at
production sites. However, unstable power supply conditions
may result in corrupted data, which can cause a significant
impact on product quality. To avoid such risk, UPSs havebeen increasingly used in production facilities. As describedabove, UPSs are used in various locations and are required
to be highly reliable in supplying power to mission-criticalapplications. Also, demand for more efficient power supply
equipment has been increasing in response to the increase of
initiatives for achieving carbon neutrality by 2050.
To meet such demands, SANYO DENKI developed
the high-efficiency, high-performance SANUPS A23D as
the successor to the SANUPS A23C (1) double conversion
online UPS (hereinafter, “current product”). This article
introduces the features of this new product.

Fig. 1 SANUPS A23D 100 kVA model

2. Product Overview
The newly developed SANUPS A23D is available in four

Maintenance bypass circuit

models with output capacities of 30, 50, 75, and 100 kVA.

Bypass circuit

Figure 1 shows the appearance of the 100 kVA model andFigure 2 shows a basic circuit configuration of the SANUPS
A23D. Under normal power conditions, the new product,with its double conversion online topology, converts AC
power (grid power) into DC power internally. The converted
DC power is then divided into two: one of them charges the
UPS battery, and the other is converted back to AC power

AC
input

RectifierAC switch
InverterAC
outputDC input(Battery)Fig. 2 Basic circuit configuration

via the inverter and supplies power to electrical equipment.
The double conversion online topology is highly reliable as

SANYO DENKI Technical Report No.54 November 2022

24

3. Features

60% or lower load levels. This reduces transfers to battery

3.1 High efficiency

preventing battery wear and degradation. Figure 4 compares

power under unstable input power supply conditions,

To further improve the efficiency of the current product,

the AC input voltage range of the current and new products.

a 2-phase modulation was used in the rectifier and inverter

Specifications for other rated output voltages are given incontrol system. This 2-phase modulation stops switching

Table 1.

devices sequentially in phase order in approximately 1/6
the cycle of the input/output frequency, leading to reduced
switching loss and improved efficiency. However, when+15%

AC input voltage range

shifting between the switching devices to stop, a large
fluctuation will occur at the neutral point shown in Figure

200 V

Powered by grid

3. Moreover, if the rectifier and inverter control timings are
not synchronized, a large circulating current will flow via
the neutral point. These issues will lead to lower efficiency
and higher costs due to increased filter circuit capacity.
With this new product, the 2-phase modulation timings of-15%
Range extended

Poweredby battery

Note: At load levels ≤ 60%-30%
Current

the rectifier and inverter have been synchronized. Also, theA23D

Fig. 4 Wide input voltage range

2-phase modulation period and AC filter circuit constant
have been optimized. These improvements have reduced
neutral point fluctuations and suppressed circulating
current, improving efficiency without additional cost. The

3.3 Walk-in feature

new product achieves an industry-leading* conversion

Some applications require an emergency power supply

efficiency of 94% or higher (max. 95.6%), which suppresses

system combining an emergency generator and a UPS as

power consumption and heat generation, reducing running

shown in Figure 5 to provide an uninterrupted, long-termcosts and CO2 emissions.

power supply in the event of a power outage. With thissystem, in the event of an outage, power is first supplied
from batteries, meanwhile, the AC input of the UPS is

Filter circuit
AC
input

RectifierInverterAC
outputswitched from grid power to the generator output. After
that, the generator will power the connected facilities via
the UPS. If the output power from the generator rapidly

Neutral point

increases during this switchover, the voltage fluctuatessignificantly and the UPS transfers back to battery power.

DC input(Battery)Fig. 3 Simplified A23D circuit block diagram

To prevent this from happening, customers needed to selecta high-capacity generator to reduce voltage fluctuations.
In response, this product has a walk-in feature that
gradually receives power from a generator. Figure 6 shows
the voltage and current waveforms when the walk-in

3.2 Wide AC input voltage range

feature is used. This function can suppress sudden power

With the current product, if a voltage dip below the AC

fluctuations in the generator during power restoration,

input voltage range occurs frequently, charging does notallowing customers to build economic emergency powercomplete in time, leaving the battery not fully charged. If a

supply systems by not requiring extra capacity of apower outage occurs under this condition, the UPS cannot

generator.

supply sufficient power to the load equipment. Moreover,a frequent battery discharge will degrade the battery,requiring replacement more frequently.

↓山洋電気TR図版用_文字スタイル

In response, this product is designed to operate in a wider
AC input voltage range. In the case of 200 V rated output
voltage, while the voltage range of the current product

25

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supports a lower limit of -15% from the rated voltage, theCondens

new product supports an extended lower limit of -30% at

英語版用

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Times Ten

Development of the SANUPS A23D Online UPS

5. Conclusion

Transfer switch
A23D

This article introduced an overview and the features ofGrid power
AC
input

RectifierInverterAC
outputdeveloped.
The new product has the following features.

DC input(Battery)Emergency
generator

the SANUPS A23D uninterruptible power supply we newly(1) Industry-leading* conversion efficiency of 94% or higher(2) Wide input voltage range to suppress battery wear andFig. 5 Emergency power supply systemdegradation(3) Walk-in feature for receiving power gradually from thegenerator(4) Reduced maintenance costs

AC input voltage

AC input current

With these features, the new product can suppress battery
wear and degradation, keeping the battery charged andready to supply power to load facilities in the event of apower outage. The product also helps customers reduce

AC output voltage

costs on the generator, operation, and maintenance.

AC output current

provide more products to meet the needsof ourcustomers.
↓山洋電気
TR図版用
_文字スタイル

SANYO DENKI will continue to swiftly develop andWithRectifiergenerator
startsconnected

Walk-in feature* Based on our own research as of March図版の文字
10, 2022, conducted123
among UPSs on the market with the same topology and英語版用
equivalent voltage, capacity, and backup
time.
CondensFig. 6 Walk-in feature

英語版用

Times Ten

References(1) Shinichi Morita and 4 others: Development of SANUPS A23C

3.4 Reduced maintenance costs
As for the replacement, the expected product life of theMedium-Capacity UPS
SANYO DENKI Technical Report No. 17 pp. 12-14 (2004.3)

current product is 15 years, but some parts such as a cooling
fan and electrolytic capacitor need to be replaced during thisperiod. The replacement cycle for these parts is 10 years,
which incurs maintenance costs. Moreover, since theseparts are mounted on the interior and top of the UPS, their↓山洋電気TR図版用_文字スタイル
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replacement is time-consuming and requires shutting down

Condens

the UPS for a while.

英語版用

The expected life of the new product is also 15 years, but

Times Tenredesigning the cooling fan and electrolytic capacitor madethem replacement-free during this period. This reduces
the cost and time required for part replacement. Althoughsome parts such as fuses and relays need to be replaced after
10 years, they have been relocated to places where they canbe easily replaced, enabling quick replacement.

4. Specifications
Table 1 shows the electrical specifications of the new
product.

SANYO DENKI Technical Report No.54 November 2022

26

Table 1 Electrical specifications
Item
Outputcapacity

Model
Apparent power
Active power

A23D303

A23D503

A23D753

A23D104

30 kVA

50 kVA

75 kVA

100 kVA

27 kW

45 kW

67.5 kW90 kW

Topology

Double conversion online

Cooling system

Forced air cooling

RectifierHigh power factor converter

Inverter

High-frequency PWM, instantaneous waveform
control

AC input

No. of phases/wires

3-phase 3-wire

Rated voltage

200/210/220 V

Same as AC output

Voltage range

200 V ±15% / 210 V ±10% / 220 V +5%, -10%

At load levels ≤ 60%, the lower limit is-30%.

Frequency

50/60 Hz

Frequency range

Within ±5% of rated frequency

Operation guaranteed within this range

Current harmonic distortion

5% or less

At rated output
At rated output

Input power factor

0.98 or more

No. of phases/wires

3-phase 3-wire

Rated voltage

200/210/220 V

Voltage regulation

Within ±1% of rated voltage

In grid operation

Rated frequency

50/60 Hz

Same as AC input

Frequency regulation

Within ±0.1 Hz of rated frequency

At free run (asynchronous)

Grid synchronized range

200/210 V ±10%, 220 V +5%, -10%
Within ±1% of rated frequency(Can be set to ±2/3/4/5%)

Voltage harmonic
distortion
AC output

Remarks

At linear load

At rated input

At rectifier load 5% or less

Voltage unbalance
Load power
factor

2% or less

At rated input and 100% rectifier load

2% or less
Rated

0.9 (lagging)

At 100% unbalanced load

Variation range

0.7 to 1.0 (lagging)

Abrupt input
voltage change

Within ±2% of rated voltage

Loss/return of input power

Abrupt loadchangeWithin ±3% of rated voltage

For 0⇔100％ load step changes

Output transfer

Within ±3% of rated voltage

During transfer from bypass to inverter

Inverter

125% (for 10 min), 155% (for 1 min)At rated input and rated load power
factorBypass

200% (for 30 s), 800% (for 2 cycles)

At rated input and rated load power
factorOvercurrent protection

Uninterrupted transfer to bypass at approx.
155% or more

Automatic retransfer after restored
to normal condition

Acoustic noise

65 dB or less

1 m from front of UPS, A-weighting(At linear load)

Heat dissipation

2.1 kW

2.9 kW

4.4 kW

5.8 kWAt rated output, after battery charging
completed(2)Cooling airflow

11 m3/min

15 m3/min

23 m3/min

30 m3/min

At rated output, after battery charging
completed(2)Battery type

Small-sized valve-regulated lead-acid (VRLA) battery

Ventilation rate required in battery panel(3)1.5 m3/min

Operating environment

Ambient temperature: 0 to 40˚C
Relative humidity: 30 to 90% (non-condensing)Transient voltage
fluctuation(1)Overload
capability

2.4 m3/min

3.6 m3/min

4.8 m3/min(1) Complies with the transient voltage fluctuation characteristics (classification 1) in JEC-2433:2016(2) Calculated using conditions of the rated load power factor, a 40°C room temperature, and a 30°C outside temperature.
(3) Calculated using the maximum charge current of the UPS.

27

SANYO DENKI Technical Report No.54 November 2022

Development of the SANUPS A23D Online UPS

AuthorHiroaki Miyoshi
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Yuji Wada
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Naoya Nakamura
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Satoshi Furihata
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Katsutoshi Tanahashi
Design Dept., Power Systems Div.
Works on the mechanical design of power supplies.

Takuya Ota
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Shohei Ohashi
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Minoru Yanagisawa
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Mika Takehara
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

SANYO DENKI Technical Report No.54 November 2022

28

New Product Introduction

Development of the SANUPS A11N
Online UPS
Makoto Kitazawa

Hiroshi Yamada

Hirofumi Kimura

Takeo Murai

Takuya Ozawa

Shogo Yoshinaga

Nobuya Otsuki

Hiroyuki Hanaoka

1. Introduction

3. Product Overview

Nowadays, devices that are designed to protect people,

The SANUPS A11N is available in two types: a single

such as ICT equipment used in social infrastructure andunit type that has a single 5 kVA base unit with AC output

security and maintenance facilities, are firmly rooted

outlets on the back of the unit or a parallel connection

in a wide range of fields. Downtime of these electronic

type that comes with a power distribution unit and isdevices can cause significant losses or impact society andscalable up to 20 kVA by combining up to four base units

the economy. Therefore, the reliability of uninterruptiblein parallel. The single unit type can be mounted verticallypower supplies (hereinafter, “UPS”) that provide backup

and horizontally, and both the single unit type and parallel

power to these electronic devices has also become extremely

connection type can be mounted on 19-inch racks. Figure 1

i mpor tant. Moreover, f rom the viewpoint of global

shows a 5 kVA model of the single unit type, Figure 2 shows

initiatives to reduce CO 2 emissions, the development of

a 10 kVA model of the single unit type, and Figure 3 shows

high-efficiency UPSs has been demanded.

the parallel connection type.

In response to these demands, SANYO DENKI has
developed the new SANUPS A11N UPS capable of parallel
operation with ease. It features improved reliability andcapacity scalability.
This article provides an overview of this new product.

2. Development BackgroundIn recent years, with the popularization of cloud services,
data centers and their power supplies have become larger insize. With teleworking being common due to the spread of

Horizontal mount

Vertical mountinfectious diseases, small-scale network equipment is also
expected to operate continuously, and this led to increasing
demand for highly reliable small-capacity UPSs. In lightof this, SANYO DENKI employed a parallel redundancy
system with proven track records to achieve even higher
reliability.
To supply high-quality power, we adopted the double
conversion online topology. Moreover, in response to
demand for improved efficiency, we set an efficiency targetof over 94%, which is industry-leading* among UPSs using
this topology.
Mounted in a rack

Fig. 1 Single unit type 5 kVA model

29

SANYO DENKI Technical Report No.54 November 2022

Development of the SANUPS A11N Online UPS

and load sharing between units are controlled using “fullyautonomous control” technology we have accumulated.
Operations such as unit start and stop, displaying
measurement information on LCD, and external signaltransmission can all be controlled as a single UPS system.

4.1.2 Achieves high reliability with parallel
redundancy
In the case of the parallel connection type, as long as there
is an unused capacity of one unit (5 kVA) extra for the load,

Fig. 2 Single unit type 10 kVA model

parallel redundant operation can be performed using one
unit as a spare, further increasing the reliability.

4.1.3 Battery management function
The UPS performs battery self-tests automatically at
regular intervals, preventing malfunction due to battery
run-out in the event of a power failure. And even in theunlikely event that an operator forgets to reinstall thebattery back during maintenance work, abnormalities
can be detected by periodically monitoring the battery
connection status. Also, the new product boasts improved
reliability with various battery management functions suchas battery life notification and display of total battery runtime, charging rate, and estimated backup time.

4.2 Easy maintenanceAs shown in Figure 4, the product employs modularized

Fig. 3 Parallel connection typeplug-in battery packs and inverter modules, which can beeasily removed from the front of the unit for increased
maintainability.

Considering use not only in Japan but also in global
markets, the input/output voltage can be set to single-phase200, 208, 220, 230, or 240 V.

Battery pack

Inverter module

By using a power distribution unit with a transformer, it isalso possible to connect to 100 V systems and single-phase3-wire systems.
The UPS uses the double conversion online topology,
which provides high-quality power independent of the input
voltage and frequency, while also achieving high efficiency.

4. Features
4.1 High reliability
4.1.1 Parallel operation with fullyautonomous control

Fig. 4 Battery pack and inverter module

Having a central control unit for parallel operation
control could hinder the reliability because the system

In the unlikely event of a failure, the failed UPS unit canfailure rate is influenced by common components. With thebe replaced without interrupting output during parallel

SANUPS A11N, the synchronization of each unit’s voltage

redundant operation while maintaining power supply from

amplitude, phase, and frequency as well as cross current

the inverter. Moreover, the SANUPS A11N is equipped

SANYO DENKI Technical Report No.54 November 202230

with an internal bypass circuit, which allows module

The display employs a 16 × 2 character transparent LCD

maintenance or replacement to be carried out while(with characters lit up) for high visibility regardless of thecontinuing to supply grid power even not during redundant

brightness in the installation location. The display language

operation.

can be selected from English and Japanese from the settings

In addition, both the inverter module and battery pack weighmenu.

less than 18 kg to reduce the workload of maintenance staff.

4.3.3 Battery cold start
4.3 Specifications suitable for wider
applications
4.3.1 Wide input range

Even when grid power is unavailable and the UPS is notoperating, the UPS can be started by battery to supply AC
power, serving as an emergency power source.

At full load level, the UPS tolerates input voltage ranging
from -20% to +15% of the rated voltage. At low load levels,

4.4 Industry’s highest efficiency*

the UPS can handle a wider -40% to +15% range of input

By using a 3-level inverter with proven track records

voltage and maintain power supply without switching toand by performing tuning to match the latest switchingbattery operation. In addition, by setting to Fixed Frequency

semiconductor device, this product achieves a maximum

mode, the UPS tolerates input frequency ranging fromefficiency of 95.1% (94% at rated output), which is best-

40 to 120 Hz and supplies 50/60 Hz output power. These

in-class in the industry among CVCF (Constant Voltage

wide input voltage and frequency ranges allow the productConstant Frequency) systems. This reduces running costs

to be used even in regions with unstable grid power. And

and contributes to CO2 emissions reduction.

asynchronous startup is possible when Fixed Frequency
mode is selected, allowing an output frequency of 60 Hz tobe obtained easily even in regions with an input frequency of

4.5 Communication interface
The new product offers various interfaces to support

50 Hz, for example.

customers’ systems.

4.3.2 LCD Panel

4.5.1 Management of personal computers(PC)

The LCD panel is modularized and can be connected
to any unit during parallel operation, allowing system

By connecting the unit’s USB port (USB Type-C) to

information to be obtained even if the panel is connecteda c o mput er a nd u s i n g t he S A N U P S S O F T WA R E

to a failed and disconnected unit. Figure 5 shows the LCD

STA NDA LONE U P S ma nagement sof t wa re f reely

panel and some display examples.

available for download from our website, automatic
shutdown of computers in the event of a power outage can be
configured easily.
Moreover, using the optional SANUPS SOFT WARE
UPS management software or LAN Interface Card can help
build even more flexible, powerful computer management
and network environments.

Appearance

Fig. 6 LAN Interface Card

In English

In Japanese (kana)Fig. 5 LCD panel

31

SANYO DENKI Technical Report No.54 November 2022

Development of the SANUPS A11N Online UPS

4.5.2 External communication signals(Dry contact output interface)

2
1
8
3
11
15
4
7

T he SA N UPS A 11N featu res 6 t y pes of ex ter na lcommunication signals. Signals “AC input error” and “ACS1

output” are two-way outputs that can both turn on and off
when activated. Signals “low battery voltage,” “inverter

S2

output,” “bypass output,” and “device error” are for turning14

on only, but the output can be inverted from the settings menu.
Moreover, for “low battery voltage,” “AC output,” “bypass

S3

output,” and “device error,” contact signals can be made

S4

5
12
6
13
9
10

independent with a switch.
This not only enables the new product to replace the current
product in an existing system but also comes in handy when

S1〜S4

building a new system.

AC input errorCOM
Low battery voltageCOM
AC output
COM
Inverter output
Bypass Output
COM
Device error
COM
UPS shutdown：Dry contact signal isolation switches

Fig. 7 Dry contact output interface

4.5.3 Remote ON/OFF
The product is equipped with a two-way switch input of

5. Circuit Configuration

remote ON and remote OFF. This can be changed from thesettings menu so that only the remote ON is used where
output starts and stopped when the switch is pressed andFigure 8 shows the circuit block diagram for the SANUPS

released, respectively.

A11N 5 kVA model.

4.5.4 EPO (Emergency Power Off)You can connect a UPS emergency stop switch to thisterminal. Moreover, contact input logic can be changed fromthe settings menu.

Maintenance bypass MCCB

Maintenance bypass circuit

GroundMain
MCCB

RectifierOutput transfer switch

AC input

FilterBypass circuit

Inverter

FilterInverter module

AC output（L6-30R）

Batteryswitch（IEC C13）

Charger（IEC C13）

Control circuit
Interface

Fuse

Battery

Optional
card

External interface

External battery connector

Fig. 8 Circuit block diagram (single unit type, 5 kVA)

SANYO DENKI Technical Report No.54 November 2022

32

5.1 Main circuit configuration
The SANUPS A11N consists of components such as arectifier, inverter, charger, and battery.

is employed for communication between units and forcommunicating with the LCD.
With CAN communication, it is necessary to assign acommunication ID beforehand. Previously, communication

5.1.1 Rectifier

IDs used to be assigned either manually or automatically

Use of a high input power factor chopper has improved thewith unique, low-speed communication where only the

UPS input power factor, widening its voltage and frequency

communication line is shared. The SANUPS A11N assigns

ranges. Moreover, with the chopper also working as acommunication IDs automatically with high speed using

battery booster, the number of parts has been reduced.

CAN communication by devising the communication
procedure.

5.1.2 Inverter
As mentioned in section 4.4, this product has a 3-level
inverter. This scheme provides a near sinusoidal output
waveform, allowing the size of the LC filter for converting

5.3 Electrical characteristics
Table 1 shows the standard specifications of the SANUPS
A11N 5 kVA model.

the output waveform to sinusoidal to be reduced. Moreover,its switching has low voltage fluctuations, reducing switchinglosses and noise from the unit. These enabled a smaller
reactor and improved efficiency.

6. Conclusion
This article provided an overview of the development of
the SANUPS A11N double conversion online UPS.

5.1.3 Charger

We believe that its high reliability, specifications

The current product uses a PW M-dedicated IC incompatible with a wide range of applications, and industry-

controlling the charger, but the new product employs digital

leading* efficiency can contribute greatly to customers’

control. This enables flexible control regardless of conditions

peace of mind and safety as well as to protecting customers’such as the battery type and use of external batteries.

assets in a wider range of markets than before.
In the future, infrastructure using ICT technology will

5.2 Control circuit configuration
5.2.1 Control ICs and non-volatile memory
incorporated into a single chip

become more diverse and involve various new fields moredeeply. It is also expected that environmental awarenesswill grow further, raising the demand for energy savings and

The current product uses two control ICs in assigningfacilitating the introduction of environmental regulations

basic control and parallel control to a high-speed DSP andboth domestically and overseas. This will most likely

monitoring, measurement, communication, and display

generate demand for UPSs with higher reliability andtasks to a CPU, where information is conveyed by serial

efficiency.

communication. Also, it uses a non-volatile memory to store

We will continue to quickly develop products to meet

failure log and settings information, where reading andthese market demands and provide products that fulfill our

writing are done by serial communication.

customers’ needs.

With the new product, all processing tasks, including
control processing, are handled by a single CPU, andsettings information is stored in data flash memory on theCPU. Incorporating these tasks into a single chip reduces
the risk of control delays due to delayed informationtransmission or failure history writing errors resulting froma sudden loss of control power.
Moreover, the memory capacity has been expanded,
increasing the number of failure history items that can besaved from 4 to 30 and operation history items from 8 to 120(60 items can be displayed on LCD panel).

5.2.2 Unit-to-unit communication
CAN bus (Controller Area Network: highly reliablecommunication protocol developed for automotive LANs)

33

SANYO DENKI Technical Report No.54 November 2022

* Based on our own research as of June 30, 2022, among online
UPSs on the market.
The company names and product names listed in this article are thetrademarks or registered trademarks of their respective companies.

Development of the SANUPS A11N Online UPS

Table 1 Standard specifications of SANUPS A11N (single unit type, 5 kVA)
Items

Type

Ratings and characteristics

Model

A11N502

Topology

Double conversion online

Inverter

High-frequency PWM

Cooling system

AC
input

Grid synchronous

Forced air cooling

Rated voltage

200 / 208 / 220 / 230 / 240 V

Same as output voltage
Voltage range: Within -40% to +15%
of rated voltage(Varies with load level)

Rated frequency

50 / 60 Hz

Auto-sensing or fixed-frequency mode
Factory setting: auto-sensing mode

No. of phases/wires

Single-phase 2-wire

Max. output capacity

5.5 kVA or lessMax. capacity during battery recovery
charging

Power factor

0.95 or more

At rated output
When input voltage harmonic
distortion < 1%

Rated capacity

5 kVA / 4.5 kW

Apparent power / active power

No. of phases/wires
Rated voltage

Single-phase 2-wire
200 / 208 / 220 / 230 / 240 V

Voltage waveform

Sinusoidal

Voltage regulation

Within ±2% of rated voltage

Rated frequency

50 / 60 Hz

Frequency regulationAC
outputRemarks

Voltage harmonic distortion

Loss/returnof input power

Within ±1 / 3 / 5% of rated frequency

In free run (asynchronous):
Within ±0.5%

3% / 7% or lessAt linear load / rectifier load,
at rated output
For 10⇔100% load step changes

Within ±5% of rated voltage

Abrupt input
voltage change
Response time

Load power factor

At rated output
Auto-sensing or fixed-frequency mode
Factory setting: auto-sensing mode

Abrupt loadchangeTransientvoltagefluctuation

User-selectable.
Factory setting: 200 V

At rated output
For ±10% abrupt changes

5 cycles or less

Excluding when loads are removed

0.9 (lagging)

Variation range: 0.7 (lagging) to 1.0

Efficiency

94% or greater

For reference purposes only

Overcurrent protection

110% or greater

Automatic transfer to bypass

Overload
capability

Inverter

110% / 118%

1 min / instantaneously

Bypass

200% / 800%

30 s / 2 cycles

Type

Small-sized valve-regulated lead-acid(VRLA) battery

Battery
Backup time
Heat dissipation
Acoustic noise
Leakage current

5 min

At a 25°C ambient temperature,load power factor of 0.9, using new,fully charged batteries.

287 W

At rated output after battery recovery
charging

45 dB or less

1 m from front of UPS, A-weighting

51 dB or less

1 m from front of UPS, A-weighting,at start of charging

5 mA or less

3 mA or less under the setting without
asynchronous operation

SANYO DENKI Technical Report No.54 November 2022

34

Development of the SANUPS A11N Online UPS

AuthorMakoto Kitazawa
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Hiroshi Yamada
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Hirofumi Kimura
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Takeo Murai
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Takuya Ozawa
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Shogo Yoshinaga
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

Nobuya Otsuki
Design Dept., Power Systems Div.
Works on the mechanical design of power supplies.

Hiroyuki Hanaoka
Design Dept., Power Systems Div.
Works on the development and design of power supplies.

35

SANYO DENKI Technical Report No.54 November 2022

Feature: Expand into Wider Markets in Depth

Expand into “Wider Markets in Depth”
̶Understand customers “in depth” in “wider” applications,and develop technology and products together̶Masahiro Yamaguchi

Tsuyoshi Kobayashi

1. Introductionused primarily in manufacturing applications and have been

2.1 High-speed technology for machine tools
Servo motor for driving machining
center spindles
2.1.1 Product overview

optimally customized for each customer. To deliver optimal

Motors for driving machining center spindles must be

customization, it is vital to know our customers well andcapable of variable speed operation up to the high-speed

deeply understand the problems they have and the solutions

range and deliver high-torque performance to handle

they seek, and share a clear image of their ideal goal. In recent

various machining processes. Also, it is important toyears, our products have been used in applications besides

improve acceleration and deceleration performance tomanufacturing equipment, and our application range has been

reduce spindle start and stop time. In addition, spindle

expanded.

motors are required to deliver high efficiency with low loss

Servo Systems products have traditionally been widelyThis article first introduces two examples of customized

for energy-saving processing.

products for manufacturing applications that were realized

To meet those requirements, we developed a high-torque,through a deep knowledge of the customer. One is high-speed

low-inertia servo motor specialized in driving machine

motors for machine tool spindles and the other is a servo

tool spindles. Figure 1 shows the appearance of the motor.

product for spring forming machines, which were the cases weThis servo motor is an interior permanent magnet (IPM)

solved their issues together with a great understanding of oursynchronous servo motor (IPM motor), and the permanentcustomers.

magnet is embedded into the rotor. This servo motor

Next, we will introduce two non-manufacturing applications

contains relatively little magnet material and is capable ofin welfare and medical equipment. Powered wheelchairsdelivering high torque up to the high-speed range, as welland radiation therapy equipment are the two examples

as high efficiency with little power loss. The rotor momentof using Servo Systems products, which we worked onof inertia is also low, ensuring outstanding acceleration anddesigning mechanisms and performance from the perspective

deceleration characteristics(1). This greatly contributes toof wheelchair users and radiotherapy patients from theimproved machine tool performance and energy savings.

beginning of the development stage with our customer.

2. Custom Products for Manufacturing
Applications Realized by Gaining
a Deep Knowledge of the Customer
This chapter introduces two examples in which we solved
problems together with the customer by gaining a deep
understanding of their problems with machine tools for
manufacturing use. The first one is the development of a
servo motor for driving machining center spindles, and thesecond one is the customization technology to incorporate
some of the functions of the customer’s spring forming
machines into our servo amplifier.

Fig. 1 Motor appearance

SANYO DENKI Technical Report No.54 November 2022

36

2.1.2 Achieving both variable speed
operation up to the high-speed range
and torque performance
In addition to the torque generated by the permanent

Through gaining a deep knowledge of the customer’sequipment, we worked together and further deepened ourtechnologies to solve problems and contribute to improving
machine tool performance.

magnet, IPM motors are capable of generating torque(reluctance torque) resulting from the difference in rotor
magnetic reluctance. Using these characteristics, we wereable to generate high torque in a wide speed range up to highspeed, helping to realize a spindle servo motor with little
power loss.

2.2 Customization technology for machine
tools Spring forming machines
2.2.1 Overview of equipment
Spring forming machines produce springs by feeding
linear or rod-shaped spring material with rollers, and coiling

IPM motors have permanent magnets embedded into

the material at equal intervals. Springs are often used as

the rotor, making it easy to prevent the magnet scattering

important parts involved in ensuring the safety of humancaused by centrifugal force. Variable speed operation up to

lives, requiring high and uniform durability, as well as high30,000 min-1 is also available.

machining precision for the equipment.

2.1.3 High-acceleration/deceleration
operation achieved through low inertia(2)Itaya Engineering Ltd. a leading spring forming machine

Figure 2 shows the appearance of equipment from The
manufacturer, and one of our customers.

With machine tools, it is necessary to reduce the startup
time until spindle machining speed is reached, and perform
sharp reversal operation quickly when performing tapping.
High-acceleration/deceleration operation is also importantto reduce cycle time. This new IPM motor has been
optimally designed to minimize rotor moment of inertia andincrease torque, achieving high-acceleration/deceleration
characteristics.

2.1.4 Low-loss, high-efficiency design
Power loss (iron loss) inside the motor’s iron core
generally increases at high speed. With our new IPM
motor, the shape and material of the iron core were revised
to minimize iron loss at high speed. Also, the reluctancetorque is optimally controlled based on the rotational speed

Fig. 2 Spring forming machine(Image source: The Itaya Engineering Ltd.)of the motor to reduce power loss and improve efficiency.
Our new motor also has a low rotor moment of inertia,
resulting in less power consumption during accelerationand deceleration. These improvements contribute greatly toenergy savings in machine tools.

Generally, ball screws or rack and pinions are used toconvert motor rotation into linear motion.
By using a simple linkage configuration as shownin Figure 3, the customer has reduced the number of
mechanical parts and improved equipment productivity.

2.1.5 Environmental durability
and maintainability

Rotational motion

Machining centers normally perform machining using

Linearreciprocating
motioncutting oil, and cutting oil is scatters around the drive
motors. For that reason, materials with high oil resistance isused for motor parts. The design also enables easy cleaning
and replacement of the cooling fan and other components.
Such design featured in environmental durability andmaintainability contributes significantly to improving the

Drive wheel

environmental durability of machine tools and reducing
maintenance time.

37

SANYO DENKI Technical Report No.54 November 2022

Fig. 3 Simple linkage configuration

SpringformingExpand into “Wider Markets in Depth” ̶ Understand customers “in depth” in “wider” applications, and develop technology and products together ̶

2.2.2 Compatibility with new equipment
without changing the controller
To achieve the linkage configuration shown in Figure 3,
the controller uses virtual cam control. Virtual cam control
converts linear position commands to angular positioncommands.
Machines that process more precise or complex shapes
need more axes, and it is difficult to perform processing for
all axes within the command update cycle.
To solve this issue, the virtual cam control that had been
performed by the controller was installed in the servo
amplifier. By allotting functions with the servo amplifier,the controller load is reduced so that all axes can be
performed.
Ga i n i ng a deep u ndersta nd i ng of, a nd opti ma l ly
customizing the customer’s functions in this way contributed

Fig. 4 In-wheel motor for wheelchair(example of installation in a wheelchair)

3.1.2 Required features of the motors
We made the following improvements to develop a servo

to the development of new equipment without significant

motor for wheelchairs.

changes to the controller.

(1) High torque characteristics in the low-speed range

3. Customization with Deep
Involvement in Welfare
and Medical Applications

the weight of the user, accelerating performance, andServo motor torque characteristics were set by specifying
maximum speed. The maximum rotational speed was
reduced compared to the standard servo motors to achieve
higher torque in the low-speed range.

In this chapter, we will introduce examples of welfare andmedical applications, two non-manufacturing applications.

(2) Dustproof and waterproof performance

The powered wheelchairs and radiation medical equipment

The joints of the motor are waterproofed to achieve highare examples of using servo systems products, which wedust and water protection, even when used in the rain or on

worked on designing mechanisms and performance frommuddy or gravel roads.

the perspective of wheelchair users and radiotherapy
patients from the beginning of the development stage withour customer.

(3) High efficiency, low heat generation
Since the wheelchair is powered by a battery, the higher
efficiency of the motor directly leads to an increase in the

3.1 Technology that promotes people’s healthIn-wheel motor for powered wheelchairs
3.1.1 Product overview

driving distance. The low heat generation of the motor is

Figure 4 shows a powered wheelchair developed as ain industrial motors, high efficiency and low heat generation

joint project with a wheelchair manufacturer. SANYO

also required in case users touch them with their bare hands.
Thanks to low-loss design technology which we cultivatedwere both achieved.

DENKI was responsible for designing the in-wheel motor
and peripheral mechanisms. The motors are mounted in(4) Silence and weight reduction

the center of the wheels of the powered wheelchair, and the

To ensure comfortable use of powered wheelchairs, wemain mechanisms are the clutch, brake, and speed reducer,

designed motors to minimize noise during motor rotation.

all of which are integrated. We designed and developedHigh motor rigidity is required for low-noise operation, while

the new motor dedicated to the wheelchair to make thosemotor weight should also be reduced for easy handling bymechanisms thin, compact, and lightweight.

operators at the same time. The motor structure was optimally

The powered wheelchair can extend the range of activities

designed to ensure both high rigidity and light weight.

for those with disabilities and support their active lifestyles.
(5) Solid encoder that won’t breakConsidering the impact during operation, the motor isequipped with a solid, hard-to-break magnetic encoder.

SANYO DENKI Technical Report No.54 November 2022

38

High-precision, high-resolution encoders required in

notify the user of errors before vibrations and abnormalindustrial equipment are not necessary for wheelchairs.

noises increase.

Instead, an encoder with the optimal performance fordriving a motor with a human operator is installed.

Axis 13.1.3 Joint development with customer
This is an example of joint development where a newent

Radiation equipm

powered wheelchair was reali zed by combining the

Axis 2

customer’s (wheelchair manufacturer) technological(A

ppstrengths with those of ours.
We worked closely with the customer from the productfunctionality to ensure that wheelchair users can use the(a) Front

products comfortably and safely. We hope that we were able
We were able to develop this new product not only byx.

A
1.5 xis
m 2
in
dia
m

et

development stage to deliver the required performance andto bring happiness to people who use wheelchairs.

roAxis 1(Approx. 3 m
in diameter)

Beam

er

)

(b) SideFig. 5 Beam irradiation direction servo mechanismand sizeusing technology cultivated in manufacturing applications
but also by incorporating a new sense of values and newtechnology different from those used in servo motors for
manufacturing use.

3.2.2 High-speed, high-accuracy positioning
with stable motion
The control axes for the beam irradiation direction

For welfare applications, we considered the performancemechanism use an ultra multipole motor with linear

required from the user’s point of view and developed the

motor coil arranged in arc and magnets arranged in

product with the equipment manufacturer to contribute to

the circumferential direction (3). The motor diameter isuser comfort.

approximately 3 m for axis 1 and approximately 1.5 m
for axis 2, making it extremely long in circumference. As

3.2 Technology that ensures treatment
with peace of mind Servo system
for radiation therapy equipment
3.2.1 Overview of equipment
The customer’s equipment is radiation medical equipment
for brain tumors and is capable of the targeted treatmentof lesions only with high-accuracy positioning and highdefinition beam irradiation.
The system has a total of 6 axes, including 2 axes tocontrol the beam irradiation direction, and 4 axes to control

shown in Table 1, there is an extremely large number ofmotor poles, with 450 poles for axis 1, and 250 poles foraxis 2. Moreover, an encoder resolution of 2.2 to 3.3 million
subdivisions is required. Our servo amplifiers can control
motors with standard 128 poles and encoder resolution of up
to 2 million subdivisions.
We were able to realize high-accuracy positioning bychanging the electrical angle calculation processing method
for current control, and offering compatibility for ultra
multipole motors and high-resolution encoders.

the cradle (bed) on which the patient lies. The axes which
control the beam irradiation direction are generally driven
by a rotary motor with a conversion mechanism such as a

Table 1 Motor pole number, encoder resolution,
and amplifier limitations

belt, but this equipment uses an arc-shaped linear servo
motor(3). By driving the arc-shaped linear motor directly,
high-accuracy positioning is possible without any backlashor drop in rigidity. Moreover, as shown in Figure 5, axis 2 ismounted on the axis 1 mechanism, and the beam irradiation
device is mounted on the axis 2 rotating bases. The tumor

Axis

Motor pole number[poles]
Motor
used

1

450

2

250

Amplifierlimitations
128 max.

Encoder resolution[subdivisions]
Encoderused2,200,000
3,300,000

Amplifierlimitations
2,000,000 max.

can be irradiated with a high-definition beam from any
direction by driving these two axes.

39

Control of this equipment tends to be unstable due to the

We worked closely with the customer from the verylarge load inertia. To stabilize high-speed positioning, weconcept stage to customize the system to provide high-simulated operation under the customer’s equipment load

speed, high-accuracy positioning with stable motion, andconditions and optimized the servo gain and filter.

SANYO DENKI Technical Report No.54 November 2022

Expand into “Wider Markets in Depth” ̶ Understand customers “in depth” in “wider” applications, and develop technology and products together ̶

3.2.3 Error notification before vibrations
and abnormal noises increase

4. Conclusion

Since there tends to be very little distance between theThis article introduced the following four examples

patient and the medical equipment, the noise and vibration

realized by harnessing the strengths of both the customer

generated by the equipment may upset the patient.

and SANYO DENKI.

With this system, encoder scale tape is attached to themotor stator periphery, and the motor position is detected(1) Servo motor for driving machining center spindleby the encoder head mounted on the moving part. If the gap(2) Servo system for spring forming machines

between the encoder scale tape and encoder head exceeds(3) In-wheel motor for powered wheelchairs

the allowable value due to equipment vibrations, operating(4) Servo system for radiation medical equipment

temperature or humidity, or degradation over time, theencoder will count incorrectly, which results in large
vibrations and abnormal noises.

The technologies and products for spindle servo motors
and spring forming machines are examples of how we have

To address this issue, we ensured to perform maintenanceachieved optimum customization for “manufacturing”

and overhauls before large vibrations occur and abnormal

applications through a deep knowledge of our customers.

noises are emitted. As shown in Figure 6, by mounting

The technologies and products for motors for powered

two encoder heads and redundantly monitoring positions

wheelchairs and radiation medical equipment are examples

from these two heads, incorrect encoder counts caused byof applications other than “manufacturing,” where wepositional displacement are detected, and errors are notified

worked with customers to consider and develop mechanisms

before vibrations and abnormal noises increase.

and servo performance from the standpoint of wheelchairusers and radiation therapy patients.
In addition to conventional manufacturing applications,

Thermostat
SignalEncoderConverterUnit

we aim to contribute greatly to “promoting people’s health”
and “restoring the global environment” by “gaining a deep
knowledge” of the needs of both the customer and the world.
References

Encoder
Signal(1) Shintarou Koichi and 2 others: Development of High-Speed AC
Servo Motors

Motor UVWSANYO DENKI Technical Report No. 11, pp. 24-26 (2001.5)(2) Yoshi Ishizuka and 2 others: Major Technologies Regarding Servo

Motor earth

Systems for Machine Tools
SANYO DENKI Technical Report No. 32, pp. 11-15 (2011.11)
Motor

Hall
SensorSignal(3) Hideaki Kodama and another: Technologies for Realizing New
DreamsSANYO DENKI Technical Report No. 50, pp. 25-30 (2020.11)

Encoder Head

Encoder Signal
Motor

Fig. 6 Image of encoder signal redundancy

AuthorMasahiro Yamaguchi
Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

In this way, by considering servo performance andfunctions from the perspective of the treatment recipient

Tsuyoshi Kobayashi

and optimally customizing motors, we have contributed

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

to the development of radiation medical equipment thatprovides safe treatment for patients.

SANYO DENKI Technical Report No.54 November 2022

40

New Product Introduction

Development of Compact Multi-Axis
Integrated Linear Servo Motor Unit
Yuki Onda

Yasushi Misawa

Satoshi Inaba

1. Introduction
There are two types of linear motors: a flat type(1), (2) andYoshiki Kaneko

2. Appearance and Specificationsof the New Productcylinder type(3) (cylinder linear motors). The flat type has

Figure 1 shows the appearance of the new product, andbeen used for horizontal axes (X-Y tables, etc.) on electronic

Figure 2 shows its external dimensions. Table 1 shows thecomponent mounters and semiconductor manufacturing

product specifications.

equipment, and the cylinder type has been often used forthe vertical axes (Z-axis) on PCB drilling machines andelectronic component mounters.
The cylinder linear motor is suitable for applications that
require fast and precise motion over short distances, but
recently, its application range has been extending, such as
telemanipulation systems for cell culture pipetting(4).
This article introduces a newly developed “compact multiaxis integrated linear servo motor unit” designed for fast,
precise reciprocating motion and multi-axis applications.

Fig. 1 New product appearance(4-axis integrated unit example)

First, we’ll present the appearance and specificationsof the new product. Next, we’ll describe its features ofcompactness, light weight, high thrust and low friction (highThe new product integrates multiple axes into a single unit

precision). Lastly, we’ll look at how the product is easy towith each axis consisting of a stator, mover, linear encoder,customize in the number of axes and spacing between axes

and frame. The mover has a structure that locks rotation

to best suit the user’s application.

using a ball spline on one side of the bearing. The stator is

4.6±0.3236±0.3

Linear encoder (mounted inside)

10.7±0.593.4±0.2

04×ø4−0.012

24±0.1542.2±0.3

21±0.2Mover shaft (mover)

StatorEncoder cable

Power cable

↑N.P

Frame

Fig. 2 Dimensions of the new product

41

SANYO DENKI Technical Report No.54 November 2022

（34.5）

72±0.15

Spacing between
axes

（37）
Effective stroke

Development of Compact Multi-Axis Integrated Linear Servo Motor Unit

resin-molded with the coaxiality of the bearing support and

Wiring space

the armature coil’s inner diameter ensured. The stator alsocomes with a power connector, allowing the power cable toMagnet (mover)be connected and disconnected.

Magnetic flux
Armature coil

Table 1 Specifications of the new product
Items

SymbolUnit

Constant

Motor model no.

−−

DM04GG011A37CX00

Power supply voltage

−

V

DC 48

Spacing between axes

−

[mm]

24

Stroke length

−

[mm]

37

Rated thrust

FR

[N]

3.5

Maximum thrust

FP

[N]

11

Rated speed

VR

[m/s]

1

Maximum speed

Vmax

[m/s]

1

Encoder resolution

−

[μm]

1

Back yoke

Wiring space
20 mm

Fig. 3 Cross section view of current model(radial cross section)

OpeningWiring board
Auxiliary back yoke

3. Product Features

Opening

3.1 Increased thrust density

Magnetic flux
Magnet (mover)Thrust density is the thrust produced per unit volume, andthe greater the value, the higher the thrust with the smaller

Armature coilsize.(1)Figure 3 shows the motor cross section and gives an

Back yokeoutline of the magnetic flux of our current cylinder linear
servo motor model. The current model has a structure
combining a cylindrical magnet, an armature coil, and asquare steel sheet (back yoke), and the distance (magnetic

ø16gap) from the back yoke to the magnet is not uniform. The

Fig. 4 Cross section view of new model(radial cross section)

greater the magnetic gap, the more difficult it is for themagnetic flux to reach the back yoke, reducing the amountof effective magnetic flux affecting thrust.
Figure 4 shows the motor cross section and gives anoutline of the magnetic flux of the new product. The new

1600
Current model

product has a structure combining a cylindrical magnet,

1400

magnetic gap is uniform. With this structure, the magnetic
flux reaches the back yoke uniformly. This results in agreater amount of effective magnetic flux, increasing thrust.
As shown in Figure 5, rated thrust density and maximum
thrust density have improved by 32% and 25%, respectively,
compared to the current model.

Thrust density [kN/m3]

an armature coil, and a cylindrical back yoke, and the

+25%

1200
1000
800
600
400

In this way, the new product is a compact, high-thrust

200

cylinder linear motor that can drive machinery at high0

accelerations and frequencies.

New model+32%

Rated thrust density

Peak thrust density

Fig. 5 Comparison of thrust density

SANYO DENKI Technical Report No.54 November 2022

42

3.2 Reduced static friction thrust
3.2.1 Improved coaxiality of fixed bearing

increase the amount of effective magnetic flux affecting thethrust, leading to no winding space inside the back yoke.

If the two bearings supporting the mover are installed

This raised the need for outside winding space, therefore

with low coaxiality, an unbalanced load is applied to the

openings were made on the back yoke. However, thesebearings, increasing static friction thrust. Since both

openings resulted in unbalanced magnetic attractive force

bearings are mounted to the fixed bearing, static friction

acting on the mover, causing the mover to be attracted tothrust can be reduced by improving the coaxiality of thethe opposite side of the openings. This increases the static

fixed bearing.

friction thrust because this results in an unbalanced radial

Figure 6 shows the stator cross section of the new product.

load exerted on the bearing supporting the mover. To

With the new product, the two fixed bearings of the stator

counter this, an auxiliary back yoke was placed as shown

were resin-molded with the shaft core placed through them.

in Figure 4, optimizing magnetic balance while securing

This structure provides improved coaxiality.

winding space.
Figu re 8 shows a compa r ison of before a nd a f ter

Shaft core
Armature coil

Back yoke and auxiliary back yoke

improving the coaxiality of the fixed bearings and themover shafts, and static friction thrust with and without theauxiliary back yoke. Static friction thrust has been reducedby 70% in total, enabling a smooth motor driving, which
offers high-precision positioning.

Fixed bearing

Improved concentricity

Fig. 6 Cross section view of new product’s stator

3.2.2 Improved coaxiality of the mover shaft
As with the fixed bearings, the coaxiality of the movershaft also affects static friction thrust.
Figure 7 shows the appearance of the mover. The new
product has two mover shafts, each of which is securely
welded to the magnet housing. To perform welding while
maintaining coaxiality, the welding equipment and welding

Static frictional thrust

Fixed bearing

1

1
0.76

0.30

0
Without
auxiliary back yoke

Without
auxiliary back yokeWith
auxiliary back yoke

Beforecoaxiality
improvement

Aftercoaxiality
improvement

Aftercoaxiality
improvement

Fig. 8 Comparison of static frictional thrust

conditions were devised, which successfully improved thecoaxiality between the two mover shafts.

3.3 Customizability
Magnet housing

With the new product, each linear motor is assembled
with high precision in its fixed bearings and mover bearing
shafts, requiring no additional adjustment even when

Mover shaft(ball spline)

Mover shaft(linear bushing)

Improved coaxiality

multiple axes are combined. This design is optimized for
multi-axis configurations, allowing easy customization of
the number of mover shaft axes and spacing between axes.
This product is suitable for applications where multiple

Fig. 7 Appearance of mover

motors are used in equipment because there is no need toadjust the installation position of each axis, greatly reducing
the assembly work for customers.

3.2.3 Optimally balanced magnetic force
The current model has space for winding the armaturecoil inside the back yoke as shown in Figure 3. On theother hand, the new product has a cylindrical back yoke to

43

SANYO DENKI Technical Report No.54 November 2022

Development of Compact Multi-Axis Integrated Linear Servo Motor Unit

4. Conclusion
This article introduced the compact multi-axis integrated
linear servo motor unit which integrates multiple compactcylinder linear motors into a single unit.

AuthorYuki Onda
Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

The features of the new product are as follows.

Yasushi Misawa
1. T he product is a compact, high-thrust cylinder linear
motor. Thrust density has been improved by 32%

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

(compared with the current model) by optimizing theshape of the steel sheet (back yoke) used for the motor

Satoshi Inaba

stator. Equipment can be driven with high acceleration

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

a n d h i g h f r e q u e n c y, c o nt r i b ut i n g t o i m p r ove dproductivity for customers’ equipment.

Yoshiki Kaneko
2. T he linear motor enables smooth driving due to little
friction thrust. Static frictional thrust has been reduced

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

by 70% (compared to the current model) by improving
the coaxiality of the fixed bearings and mover shaft anddevising the magnetic circuit of the stator. It provides
stable positioning with high precision and accuracy,
contributing to higher precision in customer equipment.
3. Multiple cylinder linear servo motors can be integrated
into a single unit, offering easy customization. The
number of cylinder linear motor axes and spacing
between axes can be laid out freely according to thecustomer’s application. Moreover, no adjustments are
required when installing the unit, significantly reducing
the assembly workload for customers.
This compact, lightweight, high-thrust cylinder linear
motor capable of high-precision positioning can be flexibly
customized to suit the customer’s equipment, contributing to
the creation of new value for our customers.
References(1) Yasushi Misawa and 2 others: Development of Compact, Coreequipped SANMOTION Linear Servo Motors
SANYO DENKI Technical Report No. 37, pp. 35-38 (2014.5)(2) Hiroyuki Sato and 3 others: Development of a compact, large
thrust, low magnetic attractive force linear servo motors
SANYO DENKI Technical Report No. 41, pp. 35-39 (2016.5)(3) Yuqi Tang and another: Development of SANMOTION Compact
Cylinder Linear Servo Motor
SANYO DENKI Technical Report No. 38, pp. 42-45 (2014.11)(4) Hideaki Kodama and 5 others: Technology for Protecting People
SANYO DENKI Technical Report No. 52, pp. 29-32 (2021.11)

SANYO DENKI Technical Report No.54 November 2022

44

New Product Introduction

Development of SANMOTION GAC Servo Systems
Tsuyoshi Kobayashi

Yasushi Misawa

Kazuhiro Makiuchi

Manabu Horiuchi

Hiroki Sagara

Takeshi Miura

Tomohito Yamazaki

Masaki Tezuka

Tetsuya Okazaki

Daisuke Yamaguchi

Yuta Hanaoka

Yuuki Nakamura

Keisuke Ishizaki

Toshio Hiraide

Hideaki Nishizawa

Masaki Miyashita

1. Introduction

2. Product Overview

SANYO DENKI has developed many servo system

This chapter provides an overview of the new SAN

products over the years, and these systems have contributed

MOTION G AC servo system products including servo

to improving the value of customers’ equipment as well as

motors, encoders, and servo amplifiers.

to industrial development. Among them in particular, our
SANMOTION R AC servo systems are still used by manycustomers due to their high performance and extensive
lineup.
S er vo system s a re e s sent ia l dev ic e s t hat i mpac t

2.1 Servo motors and encoders
Figure 1 shows some of the new servo motors. Tables 1
and 2 list the servo motor lineup, and Table 3 shows the
specifications of typical servo motor models and encoder.

machinery performance, quality, and reliability, andfurther improvements in performance and functionality
are necessary. Moreover, electrically powered equipment
efficiency improvements, energy savings, and natural
resources saving are also important as measures to counter
global heating. The role played by servo systems is becoming
more important than ever for industrial development and toresolve problems facing the global environment.
In response to these expectations, we developed new(a) Medium-inertia,
40 mm sq., 100 W(GAM2A4010F0XRK0)(b) Medium-inertia,
60 mm sq., 400 W(GAM2A6040F0XRK0)SANMOTION G AC servo systems. The new servo system
offers servo motors, holding brakes, encoders, and servo
amplifiers have been renewed from SANMOTION R basedon the concepts of “powerful” and “friendly” servo systems.
“Powerful” means that high servo performance andhighly reliable products that can be used with peace of mind
in various regions and environments. “Friendly” means
products that deliver energy savings, that are compact andlightweight, that are friendly to the global environment, andthat are easy to use.
This article will begin by showing the appearance of(c) Medium-inertia,
80 mm sq., 750 W(GAM2A8075F0XRK0)

our new products and product lineup, as well as productspecifications. Next we’ll introduce the “powerful”
and “friendly” features of our new products, and thedevelopment points.

(d) Medium-inertia,
130 mm sq., 1.2 kW(GAM2AB120H0XRK0)

Fig. 1 Servo motor appearance

45

SANYO DENKI Technical Report No.54 November 2022

Development of SANMOTION G AC Servo Systems

The lineup comprises a total of 37 models, with 13 low-

connector, and the encoder connector are directly secured

inertia models ranging from a 40 mm sq., 50 W model to a

to the motor unit with screws, allowing them to be securely

100 mm sq., 1.5 kW model, and 24 medium-inertia models

fastened. The 100 mm sq. to 130 mm sq. models employ aranging from a 40 mm sq., 30 W model to a 130 mm sq.,

circular push-pull connector for easier assembling.

1.2 kW model. The lineup includes the same 31 models as

Our combination encoder lineup contains a compact,

the current SANMOTION R series, as well as new 40 mm

sl i m, batter y-less absolute enc oder w ith ma x i mu msq., 150 W, 60 mm sq., 600 W, and 80 mm sq., 1 kW models.

resolution of 27 bits, and a single-turn absolute encoder,

The 40 mm sq. to 86 mm sq. models feature an integrated
power cable and holding brake cable, and new 6 -core
integrated connector. The power and holding brakerealizing high resolution and shorter motor length.
Custom options available are with/without holding brake,
with/without oil seal, and circular/keyway shaft.

Table 1 Servo motor lineup (Low inertia)
Flange size

40 mm sq.

60 mm sq.

80 mm sq.
100 mm sq.

Power supply voltage
100 V

200 V

Servo motor
model no.

Newly added
model

50 W

✓

✓

GAM1*4005F0–

Rated output

100 W

✓

✓

GAM1*4010F0

–

150 W

–

✓

GAM1A4015F0

✓

200 W

✓

✓

GAM1*6020F0

–

400 W

–

✓

GAM1A6040F0

–

600 W

–

✓

GAM1A6060F0

✓

750 W

–

✓

GAM1A8075*0

–

1 kW

–

✓

GAM1A8100F0

✓

1 kW

–

✓

GAM1AA100*0–

1.5 kW–✓GAM1AA150*0–

Table 2 Servo motor lineup (Medium inertia)
Flange size

40 mm sq.

60 mm sq.

80 mm sq.

86 mm sq.

100 mm sq.

130 mm sq.

Power supply voltage
100 V

200 V

Servo motor
model no.

Newly added
model

30 W

✓

✓

GAM2*4003F0

–

50 W

✓

✓

GAM2*4005F0

–

100 W

✓

✓

GAM2*4010F0–

Rated output

150 W

–

✓

GAM2A4015*0

✓

100 W

✓

✓

GAM2*6010F0

–

200 W

✓

✓

GAM2*6020F0

–

400 W

–

✓

GAM2A6040F0

–

600 W

–

✓

GAM2A6060*0

✓

200 W

–

✓

GAM2A8020F0

–

400 W

–

✓

GAM2A8040F0

–

750 W

–

✓

GAM2A8075*0

–

1 kW

–

✓

GAM2A8100F0

✓

750 W

–

✓

GAM2A9075F0

–

1 kW

–

✓

GAM2A9100*0

–

750 W

–

✓

GAM2AA075F0

–

1 kW

–

✓

GAM2AA100F0–

1.5 KW–✓GAM2AA150*0

–

550 W

–

✓

GAM2AB055D0–

1.2 kW–✓GAM2AB120*0–

SANYO DENKI Technical Report No.54 November 2022

46

Table 3 Servo motor (typical models) and encoder specifications
Low-inertia: GAM1A

Servo motor model no.
Items

Medium-inertia: GAM2A

4010F06040F08075F0

A150H04010F06040F08075F09100F0A100F0 B120H0

Flange size−mm

40 sq.

60 sq.

80 sq.

100 sq.

40 sq.

60 sq.

80 sq.

86 sq.

100 sq.

130 sq.

Rated output

PR

W

100

400

750

1500

100

400

750

1000

1000

1200

Rated torque

TR

N·m

0.318

1.27

2.39

4.8

0.318

1.27

2.39

3.18

3.18

5.8

Continuous torque at stall

TS

N·m

0.353

1.37

2.55

4.9

0.318

1.37

2.55

3.92

3.92

6.0

Peak torque at stall

TP

N·m

1.18

4.8

8.5

18.0

1.18

4.8

8.5

14.3

14.7

20.0

Rated speed

NR

min-1

3000

3000

3000

3000

3000

3000

3000

3000

3000

2000

Maximum speed

Nmax

min-1

6500

6500

6500

3000

6500

6500

6500

6500

6000

4000

Rated armature current

IR

Arms

1.00

2.8

5.9

5.2

0.99

2.9

5.9

6.0

5.5

6.7

Continuous armature
current at stall

IS

Arms

1.05

2.8

5.7

3.8

0.96

2.9

5.9

6.8

6.2

6.6

Peak armature current

IP

Arms

4.1

12.0

22.0

15.5

3.6

10.8

21.4

25.7

26.5

26.5

JM

×10-4

Rotor
inertia

Without brake
With brake

Encoder inertia
MotorlengthJS

Without brake
With brake
Without brake

LL

kg·m2
(GD2/4)mm

0.0259

0.213

0.739

1.98

0.06

0.466

1.56

2.45

3.97

7.78

0.0324

0.272

0.936

2.31

0.067

0.524

1.76

2.75

4.30

8.86

0.00250.00250.00250.00250.00250.00250.00250.00250.00250.0025

93.5

110

125

156.5

68

85.5

92.0

127

128

100.5

122

132.5

155.5

193

100.5

111.5

126

153

146

135.5

0.52

1.4

2.9

5.0

0.4

1.3

2.2

3.4

4.1

5.5

0.71

1.8

3.7

6.6

0.6

1.6

3.0

4.2

4.9

7.1

WE

kg

Encoder resolution––

17-bit (131,072 steps), 20-bit (1,048,576 steps), 23-bit (8,388,608 steps), 27-bit (134,217,728 steps)

Multi-turn encoder––

Batteryless

Mass

With brake

2.2 Servo amplifier overview
Figure 2 shows some of the new servo amplifiers. The

20 A, and 30 A, and the 200 V type consists of 4 models, with
output current capacity of 10 A, 20 A, 30 A, and 50 A.

connectors for the power supply and motor power were

An EtherCAT type and analog/pulse train commandchanged to a spring-type, push-pull connector for improved

input type have been prepared for the host controller andworkability and safety than the current models.

interface. The analog/pulse train command input type is

As shown in Table 4, the lineup contains a total of 21 models
based on the power supply voltage, combined servo motor, andavailable in SINK or SOURCE type as a general-purpose
output specification.

host controller and interface specifications. The 100 V type

Table 5 shows the main specif ications of the newconsists of 3 models, with output current capacity of 10 A,

servo amplifiers. In comparison with the current model,
responsiveness has been enhanced, and servo performancehas been improved with an extensive range of control andcompensation functions.
S er vo t u n i ng c a n be per for med ea sier u si ng t he
“SANMOTION MOTOR SETUP SOFTWARE” tool
(hereinafter abbreviated to SETUP SOFTWARE) and thelinked frequency characteristics measurement function andAdvanced Tuning function.
To allow the new product to be used in various regions andenvironments, environmental durability to conditions suchas altitude and ambient temperature have been improved,
and reliability has been increased. Moreover, the product(a) 30 A
EtherCAT type
(GADSA03AH24)(b) 50 A
Analog/pulse input type
(GADSA05AA00)

has been equipped with an extensive range of monitoring
functions used to estimate remaining part life, and monitor
the power supply condition and communication quality,

Fig. 2 Servo amplifier

47

SANYO DENKI Technical Report No.54 November 2022

improving maintainability.

Development of SANMOTION G AC Servo Systems

Table 4 Servo amplifier product lineup
Power supply voltage

Compatible motors

GPO interface

100 V

200 V

Rated output

EtherCAT

Analog/Pulse

Servo amplifiermodel no.

✓–Up to 30 W–

Sinking output

GADSE01*A**✓–

Up to 30 W–

Sourcing output

GADSE01*B**✓–

Up to 30 W✓–

GADSE01*H**✓–

Up to 100 W–

Sinking output

GADSE02*A**✓–

Up to 100 W–

Sourcing output

GADSE02*B**✓–

Up to 100 W✓–

GADSE02*H**✓–

Up to 200 W–

Sinking output

GADSE03*A**✓–

Up to 200 W–

Sourcing output

GADSE03*B**–

GADSE03*H**✓–

Up to 200 W

✓

–

✓

Up to 150 W–

Sinking output

GADSA01*A**–✓

Up to 150 W–

Sourcing output

GADSA01*B**–✓

Up to 150 W✓–

GADSA01*H**–✓

Up to 400 W–

Sinking output

GADSA02*A**–✓

Up to 400 W–

Sourcing output

GADSA02*B**–✓

Up to 400 W✓–

GADSA02*H**–✓

Up to 1.5 kW–

Sinking output

GADSA03*A**–✓

Up to 1.5 kW–

Sourcing output

GADSA03*B**–✓

Up to 1.5 kW✓–

GADSA03*H**–✓

Up to 2.5 kW–

Sinking output

GADSA05*A**–✓

Up to 2.5 kW–

Sourcing output

GADSA05*B**–✓

Up to 2.5 kW✓–

GADSA05*H**

SANYO DENKI Technical Report No.54 November 2022

48

Table 5 Servo amplifier main specifications
Amplifier capacity

10 A

Items

20 A

50 A

Control power supply
voltage range

200 to 240 VAC +10%, -15%

Main circuit power supply
200 V voltage range

Single-/3-phase 200 to 240 VAC +10%, -15%; 300 VDC ±20%3-phase (singleCompatible
phase/DC inmotorsparentheses)

Up to 150 W

Main/Control circuit power
100 V supply voltage range
Compatible motors

Up to 1.5 kW(up to 750 W)

Up to 400 W

Up to 2.5 kW(up to 1.5 kW)

Single-phase 100 to 120 VAC +10%, -15%; 150 VDC ±20%

Continuous output current /Peak current–

Up to 30 W

Up to 100 W

Up to 200 W–

1.2 Arms /4.3 Arms

3.1 Arms /12 Arms

5.2 Arms /16.3 Arms

12 Arms /26.5 Arms

Altitude / Operating ambient
temperature / Vibration resistance2000 m or less / 0 to 60˚C / 6.0 m/s2

Dimensions

40 W × 160 H × 130 D

50 W × 160 H ×
130 D

85 W × 160 H ×
130 D

0.8 kg or less

0.9 kg or less

1.6 kg or less

Mass
Structure / Cooling system

Tray type /Passive air cooling

Compatible motor types•

Rotary motors•

Absolute encoders (battery-less, single-turn, and battery backup types)
Wire saving incremental encoder • HEIDENHAIN's EnDat2.2 encoder

Compatible encoders

Compliancewith standards

Performances and functions

Responsivenessand maximum applicable
resolution

49

30 A

Control functions,compensation functions
Interface•••

Tray type / Forced air cooling•Linear servo motors•

3.5 kHz (speed loop frequency response)
134,217,728 steps per rotation (27 bit)

• Tandem operation control

•

•

•

Quadrant projection compensation• Gravity compensation•

Direct drive motors

Dual position feedback control
Friction compensation• Disturbance observer

EtherCAT, analog/pulse train command input• FF vibration suppression
Model following vibration suppression
Vibration suppression for trajectory control • Adaptive notch filter• CP vibration control• Minor-vibration control• Torque command notch filter (variable width)•

Mechanical vibrations,resonance suppression
Servo tuning•••• Advanced tuning
Frequency characteristics measurement
Auto tuning responsiveness (7 characteristics, 40 levels)

Start-up, monitoring,
diagnosis• Drive recorder
Virtual motor operation
System power consumption monitoring • Input power supply monitoring• Control power supply frequency monitoring• Encoder/EtherCAT communication quality monitoring• Remaining electrolytic capacitor life
• Remaining holding brake life
• Regenerative resistor power consumption monitoring• Encoder temperature monitoring• Amplifier temperature monitoring• Relay counter• Relay sticking detection

UL / CSAUL 61800-5-1 / C22.2 No. 274-13

Low Voltage Directive /EMC Directive

EN 61800-5-1 / EN 61800-3, EN 61326-3-1

Functional safety

ISO 13849-1 PL=e, EN 61508 SIL3, EN 62061 SILCL3KC Mark

KN 61000-6-2, KN 61000-6-4

Other

CE Mark, UKCA Mark, RoHS Directive••

SANYO DENKI Technical Report No.54 November 2022

Development of SANMOTION G AC Servo Systems

3. Features

motor torque in the high-speed rotation range has been

3.1 “Powerful” servo performance
3.1.1 High-power, high-precision
servo motor

the motor.

improved by up to 7% by increasing the voltage applied to

The new product features an optimized servo motor,

By doing so, the motor output range has expanded by
15%, allowing acceleration and deceleration time to be
reduced.

holding brake electromagnetic field construction, andwinding specifications. Moreover, improvements have

SANMOTION G

been made to the connector arrangement and motor
significantly shortening the motor length. Torque density
has been improved by reducing the size of the motor,
while maintaining the high torque characteristics of the

SANMOTION R

Torque [N·m]construction, and the size of the encoder has been reduced,

Torque: +7%
Output range: +15%

SANMOTION R series. Torque density is the torqueproduced per unit volume, and the larger the value, the more

Maximum speed: +8%

torque that is produced with smaller motor.

0

2000

Figure 3 shows a comparison of peak torque density. Peaktorque density has been improved by up to 13% for low
inertia, and up to 28% for medium inertia compared to thecurrent model.

4000

6000 6500

Speed [min-1]

Fig. 4 Comparison of servo motor torque-speed
characteristics

The developed encoder is a high-resolution batteryless absolute encoder, and the resolution can be selectedfrom 17-bit, 20-bit, 23-bit, or 27-bit. Enhancing encoder
resolution has made it possible to realize stable repeat
operation and highly-responsive positioning.

3.1.3 Improved responsivenessand shortened positioning time
Figure 5 shows the closed loop frequency response forthe speed control system. The responsiveness of the current
control system has been doubled over the current model by
increasing the control cycle speed and improving the current

SANMOTION R

detection accuracy. And by improving the torque control

SANMOTION G

system, the frequency response of the speed control system

1.5

has been improved by approximately 1.6 times (3.5 kHz)over the current model.

1

2.2 kHz

0

0

□

□

Low inertia

Gain [dB]

10

10
0
W
60
-4
00
□
W
80
-7
50
□
W
10
01
kW
□
40
-1
00
□
W
60
-4
00
□
W
80
-7
50
W
□
86
-1
kW
□
10
01
□
kW
13
01.
2
kW

0.5

40
-

Peak torque density ×105[N･m/m3]

2

-3 dB
-10

Medium inertia

Fig. 3 Comparison of peak torque density

3.1.2 Extended output range

3.5 kHzSANMOTION R 3E Model
SANMOTION G

-20
100

1000

Frequency [Hz]10000

Fig. 5 Comparison of frequency response in speed
control system

Figure 4 shows a comparison of torque vs. rotation speed
characteristics (T-N characteristics). By optimizing thewinding specification, the maximum rotation speed of the

Figure 6 shows positioning settling characteristics. Using

motor has been increased from 6,000 min-1 to 6,500 min-1,

the “SETUP SOFTWARE” tuning function (Advanced

an 8% improvement over the current model. The servo

Tuning), the positioning settling time has been reduced byamplifier voltage use rate during high-speed rotation, a

1/3 over the current model by compensating the impact ofvoltage saturation condition, has been improved, and thefriction and gravity that hinders settling.

SANYO DENKI Technical Report No.54 November 2022

50

3.2.2 Reduced radiated emissions

Position deviation [pulse]

SANMOTION R 3E Model

The main cause of rising emission levels is parts that work

SANMOTION G

600

at high speed and with high accuracy. To address this, weanalyzed the PCB magnetic near field, and optimized the400pattern layout.

200

Figure 7 shows the servo amplifier (capacity: 30 A)
radiated emissions. As the obtained data in this chart shows,0
R 3E Model

-200
-3

G
0

7

the radiated emissions level in the high frequency range
Positioning complete
signalShortened
to 1/3
17

27

37

47

Time [ms]Fig. 6 Positioning characteristics

caused by reference clock signals such as those from theoscillator have been significantly lowered than the current
model. By carrying out this test using a 10 m anechoic
chamber in the new building of our Technology Center
completed in 2021, we were able to significantly shorten theevaluation period.

3.2 “Powerful” environmental durability
3.2.1 Enhanced environmental durability

VULB9168

between the current product and new product. The new
product can be used in more regions and in harsher
environments than the current product.
The higher the altitude, the more air pressure drops,
leading to lower air density, and this in turn results in adrop in heat radiation efficiency and withstand voltage. We
stipulated a design that would allow the product to be used
at altitudes twice as high as the current model, as well as

Level [dBμV/m]

Table 6 shows a comparison of environmental durability

55
50
45
40
35
30
25
20
15
10
5
0

Peak limit [PK]SANMOTION R 3E Model
SANMOTION G

Quasi-peak limit [QP]

30

100

Frequency [MHz]1000

Fig. 7 Radiated emissions (10 m, horizontal)

the applicable test method. By clearing these strict tests, wewere able to realize a product that can be used at altitudes
of up to 2,000 m. Moreover, we significantly expanded theservo motor vibration resistance to twice the 24.5 m/s2 value

3.3 “Powerful” maintainability
3.3.1 Preventive maintenance functions

for the current model to 50 m/s2. We also developed a high-We equipped the servo system with a remaining part

reliability holding brake with minimal abnormal friction

life function for the parts used in servo motors and servo

material wear, and this maintains holding torque even in

amplifiers to help with failure prevention and maintenance.

high-temperature and high-humidity conditions.

The motor holding brake is calculated from the amount ofBoth the servo motor and servo amplifier can be usedrotation when the motor is stopped by braking with respectsafely with derating specifications stipulated for each usage

to the wear limit. Electrolytic capacitor deterioration iscondition.

calculated from the main circuit power supply and servo ON
condition. The remaining life of the fan motor and relays isTable 6 Environmental durability comparison
with current product
Items

Product

AltitudeMotor
AmplifierVibration
resistance

Motor
AmplifierAmbient
Amplifiertemperature
Ambient
humidity

51

Amplifier

SANMOTION R(Current product)

SANMOTION G(New product)

1,000 m or below

2,000 m or below(may require derating)24.5 m/s2(10 Hz to 2 kHz)
4.9 m/s2(10 to 55 Hz)
0 to 55°C
90% RH or less(non-condensing,non-frozen)

50 m/s2(10 Hz to 2 kHz)
6.0 m/s2(10 to 150 Hz)
0 to 60°C(may require derating)
95% RH or less(non-condensing,non-frozen)

SANYO DENKI Technical Report No.54 November 2022

calculated from the operating time and operation count withrespect to the expected life.
Failures can be prevented by systematically replacing andoverhauling servo motors and servo amplifiers based on thisinformation.

3.3.2 Environmental diagnosis
We added functions to help with servo system installation
environment diagnosis. Table 7 shows a list of environmental
mon itor i ng item s . E r ror rate s , etc . for Et her CAT
communication and encoder communication have also been
included. These functions allow products to be used safely
and with peace of mind by conducting surveys of customers’Development of SANMOTION G AC Servo Systems

operating environments to make improvements as quickly as

efficiency, we achieved up to 9% higher efficiency bypossible.

optimizing the electromagnetic field, improving the winding

Main circuit rectifier voltage monitoring detects peakvoltage value through 3-phase full-wave rectification of thefill factor, and using low-loss materials. This resulted in up
to 48.3 % lower CO2 emissions.

input power supply voltage. Control power supply frequency

Use in combination with a battery-less absolute encoder

monitoring detects power supply frequency in 1 H zeliminates the need for battery backup for retaining multi-

increments. Monitoring of these parameters provide theturn data when the power is turned OFF. Consequently,

status of overvoltage, voltage fluctuations, and frequency

there are no batteries that need to be periodically replaced,

fluctuations, helping customers diagnose power supply

contributing to natural resources saving, reduced industrial

environments and identify the cause when errors occur.

waste, and improved maintainability.

Main circuit rectifier voltage
monitoring

V

Main circuit DC voltage
monitoringV

Control power supply
frequency monitoring

0.1 HzMotor encoder
communication error rate

-9%80-750 W□□-6%100-1 kW-7%40-100 W□−

Communication External encoder
communication error ratequality−

EtherCAT communication
error rate−

60-400 W□□

Figure 8 compares the motor length and Figure 9
compares the motor weight of the current and new models(without holding brake in both figures). As mentioned
earlier, the servo motor length and weight have been
reduced by improving the electromagnetic field and motor

150

100

150

200

SANMOTION G

Fig. 8 Comparison of motor length(Without holding brake)
7-10%

SANMOTION R

6

SANMOTION G

5
-6%

-3%

3
2
1

0%

0%

4

-21%

-7%
-12%

-20%
-26%

0
10
0

3.4 “Friendly” to (global) environment
3.4.1 High-efficiency, compact, lightweight
servo motor-8%130-1.2 kW

40-

downtime.

-15%
-11%

SANMOTION R

Motor mass [kg]This helps identify the cause quickly, reducing equipment

86-1k W

100-1k W
0□

displayed as sub-codes.

-22%

□
□

We adde d sub - c o de s to a la r m c o de s to i mprove
is subdivided up into to 15 types of cause, and these are-19%80-750 W□

3.3.3 Early diagnosis
troubleshooting when alarms occur. Each alarm code

-18%

W
60
-4
00
□
W
80
-7
50
□
W
10
01
kW
□
40
-1
00
□
W
60
-4
00
□
W
80
-7
50
W
□
86
-1
kW
□
10
01
□
kW
13
01.
2
kW

Frequency

Outputunit□

Input voltage

Monitoring name-9%60-400 W□

Medium inertia

Monitoring
item

40-100 W□

Low inertia

Table 7 Environmental monitoring items list

Low inertia

Medium inertia

Fig. 9 Comparison of motor mass
(Without holding brake)

mechanism and reducing the size of the encoder. The motor
length has been shortened by up to 11% for low-inertia

3.4.2 Servo amplifier with low loss

models and by up to 22% for medium-inertia models. The

To increase servo amplifier output, we improved the

motor weight has been reduced by up to 12% for low-inertia

maximum output current of the power device by up tomodels and up to 26% for medium-inertia models. Also, the

5%. To increase responsiveness, switching frequency of

reduced motor length and weight have led to a reduction in

the power device has been made 16% faster under normal

the amount of materials used by up to 28%.

conditions and up to 55% faster in the mode for reducing

Although shortening motor length usually reduces its

the noise caused by switching frequency when the motor

SANYO DENKI Technical Report No.54 November 202252

is stopped. Increased output current and faster switchingfrequency usually result in increased loss and lower

3.6 “Friendly” to customers
3.6.1 Makes replacement easy

efficiency. Despite this, amplifier power consumption

T he servo motor has the same f lange dimensions,has been reduced by up to 22% by replacing high power

mounting dimensions, and output shaft shape as theconsumption parts. This resulted in up to 18.9% lower CO2

SANMOTION R for mounting compatibility. The motor

emissions.

power cable and holding brake cable on the current modelMoreover, by reducing part size and optimizing thermal

were separate, but they have been integrated into a single

design, amplifier weight has been reduced by up to 5.5%

cable as shown in Figure 10, reducing the number of parts.

while maintaining the same size as the current models.

The servo amplifier has the same external dimensions
and mounting dimensions as the current model. Current

3.5 “Friendly” to operators
3.5.1 High-precision measurementof machinery characteristics
High-precision system analysis has been added to ourconventional system analysis to offer a new measurement

functionality has been retained, and newly developed
compensation and functions have been added.
By enhancing compatibility, SANMOTION G can beeasily substituted into customers’ existing equipment.

mode. Conventionally, a dedicated measurement device(servo analyzer) was used to measure machinery frequency
characteristics including servo control loop with highprecision. The new amplifier achieves high-precision
mea su rement by generat i ng si nu soida l c om ma nds,

Encoder connector
Brake connector
Power connector

calculating the frequency spectrum, and executing thefrequency analysis of SETUP SOFTWARE.

3.5.2 Optimized tuning of servo parameters
We developed Advanced Tuning, which measuresmachinery characteristics and optimize parameters for it.
Advanced Tuning automatically performs the following(a) SANMOTION R (Current product)

series of characteristic measurements and parameter
adjustments in (1) to (4).
(1) Adju st fe e dbac k c ont rol pa ra met er s u si ng t heconventional system analysis.
(2) Using friction and gravity measurement, estimate

Encoder connector
Power and brakeconnector

friction and gravity and then compensate.
(3) Using the high-precision system analysis, adjust
feedback control parameters more precisely to ensurestability.
(4) I n po sit ion i ng operat ion , adju st mo del c ont rol
parameters to improve responsiveness.
(b) SANMOTION G (New product)

This optimizes adjustments and shortens startup time,
improving ease of use.

Fig. 10 Servo motor connectors

3.5.3 Update of motor parameters
SETUP SOFTWARE is revised with a new servo motor
parameter update function. Previously, it was necessary to

The same “SETUP SOFTWARE” interface is used,

update the firmware to run servo motor models that were

improving visibility and ease of use. As shown in Figure 11,

newly added to the lineup.

the servo amplifier status and general-purpose input/output

With this new servo system, the servo motor parameters
can be updated easily by the customer on site using SETUPSOFTWARE.

53

3.6.2 Increased visibility and usability

SANYO DENKI Technical Report No.54 November 2022

status can be intuitively grasped by displaying them visuallyon the screen.

Development of SANMOTION G AC Servo Systems

model, which involved attaching a printed seal, to a
nameplate that is printed directly onto the amplifier bodywith a laser marker, eliminating the need for manual label
attachment work.

(a) Servo amplifier status display(b) GPIO status display

Fig. 11 Monitoring screens on SETUP SOFTWARE

4. Key Points of Development
To improve productivity and quality over the current
model, it was necessary to construct a test environment in(a) SANMOTION R(Current product)(b) SANMOTION G(New product)

Fig. 12 Text printed label (left) and laser-printed
text (right)

which designs which allowed products to be manufactured
on automated lines and various tests could be performed

As shown in Figure 13, the wiring for the built-in

automatically. This chapter introduces aspects of theregenerative resistor in the current model is connected todevelopment and creative ideas we incorporated into ourthe connector on the front after assembly is complete, anddevelopment work.

the work was complex. On the new product, the connector isconnected to a board inside the servo amplifier.

4.1 Increased servo motor productivity
and production quality

Wiring no longer becomes trapped, making work easier.

A ll servo motor models were constructed with analuminum frame, and the structural skeleton was unified
using a similar design. The basic construction is the same forall models, making it possible to switch between production
models quickly. Moreover, assembly of the stator and rotor,
key motor components, was automated for each process for
improved productivity.
New automatic equipment used to produce the rotating
disk module is adopted for the encoder. The rotating disk
centering and bonding processes that were previously
carried out manually are now carried out using a camera and(a) SANMOTION R
RS3A02 (current product)(b) SANMOTION GGADSA02 (new product)

Fig. 13 Built-in regenerative resistor wiring

robot, and this has greatly improved productivity.

4.2 Increased servo amplifier productivity
and production quality
4.2.1 Increased productivity

Firmware is written automatically when assembling by theautomated line robot. The weight of the write jig is greaterthan the withstand load of the robot hand, and so the jig has

As show n i n Figu re 12 , the ma i n ser vo a mpl i f ier

been installed on the robot unit. A 3 m cable is required to

nameplate has been changed from the label for the current

connect the write jig to the tip of the robot arm, but the cable

SANYO DENKI Technical Report No.54 November 2022

54

from the manufacturer is only 0.2 m long, and so cannot betimes (3.5 kHz), we were able to realize stable, highlyresponsive operation.

used.
In response to this, we produced a communication jig(2) We improved vibration resistance by 2 times for thecapable of transmitting high-speed signals corresponding

servo motor, and 1.2 times for the servo amplifier. We

to automatic writing using the robot over long distances asincreased the altitude at which the product can be usedshown in Figure 14.

from 1,000 m to 2,000 m, and expanded the operating
temperature range. Improving the environmental
durability allows the product to be used in a variety ofCablesregions, even in harsh environments.
(3) We equipped the new product with functions such as
Servo amplifier

holding brake and electronic component life prediction,and input power supply and communication quality
monitoring to help with servo system preventive

Communication jig

maintenance, and equipment environment monitoringand diagnosis. These functions have led to improved

Writing jig

machinery maintainability.
(4) We made the system smaller and lighter by reducing

Fig. 14 Automatic writing using robot

the servo motor length by up to 22%, and reducing theweight by up to 26%. We realized energy savings byreducing servo motor energy loss by up to 8%, holding

4.2.2 Increased software quality
Servo systems are used in a variety of applications.
Conditions and environments tend to be complex, and it isdifficult to carry out exhaustive testing manually.
To carry out effective and efficient testing for thisbrake power consumption by up to 44%, and servo
amplifier energy loss by up to 22%.
(5) We were able to shorten equipment startup time with
an Advanced Tuning function used to measure machine
characteristics with high accuracy, and automaticallydevelopment, we constructed a test simulator capable ofadjust servo parameters to their optimum values.

simulating the actual operating environment. We created(6) T he motor power and holding brake cables have beena template for the test pattern, and developed a tool used

integrated. The cable connector direction can also be

to run tests by automatically generating patterns based onchanged, increasing the degree of wire freedom to makecondition settings. For the test simulator, we created verticalwiring work easier.

and horizontal units, as well as a rotary unit. By anticipating(7) T he new product has exterior size and mounting

the customer’s actual equipment, we were able to carry out

i ntercha ngeabi l it y w ith the cu r rent model, a nd

various tests by using a proximity sensor, holding brake,

functionality has been retained, allowing the current

loading device, speed reducer, and external encoder.

model to be easily substituted for the new product.

This helped us to discover potential defects at an earlystage, ensuring stable quality in a short space of time.

T h i s S A NMOT ION G AC ser vo system feat u res
significantly evolved ser vo performance and higher

5. Conclusion

reliability, and can be used at high power even in harshenvironments for peace of mind. Energy savings, and size

This article provided a product overview, and introduced

and weight reductions have been realized, making the new

the features and development points of the SANMOTION

product both easier to use, and friendly to both the global

G AC servo system developed based on the concepts ofenvironment and to users.

“powerful” and “friendly.”In the future, we intend to expand the series lineup, anddevelop optimally customized products tailored to customer

In comparison with the current model, the SANMOTION
G offers the following enhancements.

applications through development with deep customer
involvement.

(1) Peak torque density improved by up to 28%, and theoutput range in the high-speed area expanded 1.15 times.
By increasing the encoder resolution by 16 times (max.
27 bit) and the speed loop frequency response by 1.6

55

SANYO DENKI Technical Report No.54 November 2022

Note 1: Current servo motors refer to SANMOTION R motors.
Note 2: Current servo amplifiers refer to SANMOTION R 3E Model amplifiers.
Note 3: EtherCAT® is a registered trademark and patented technology, licensed
by Beckhoff Automation GmbH, Germany.

Development of SANMOTION G AC Servo Systems

AuthorTsuyoshi Kobayashi

Tetsuya Okazaki

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Yasushi Misawa

Daisuke Yamaguchi

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Kazuhiro Makiuchi

Yuta Hanaoka

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Manabu Horiuchi

Yuuki Nakamura

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Hiroki Sagara

Keisuke Ishizaki

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Takeshi Miura

Toshio Hiraide

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Tomohito Yamazaki

Hideaki Nishizawa

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

Masaki Tezuka

Masaki Miyashita

Design Dept. 2, Servo Systems Div.
Works on the development and design of encoders.

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

SANYO DENKI Technical Report No.54 November 2022

56

Memo

57

SANYO DENKI Technical Report No.54 November 2022

54

November2022

https://www.sanyodenki.com/

Published in Japan on November 15, 2022 by SANYO DENKI CO., LTD.
Published semi-yearly
3-33-1 Minami-Otsuka, Toshima-ku, Tokyo 170-8451, Japan
Phone +81 3 5927 1020
Publisher Nobumasa Kodama
Editorial Board Members:
Toshihiko Baba
Editor-in-Chief
Satoru Onodera
Managing Editor
Takashi Kobayashi
Secretariat
Shiho Tsukada
Secretariat
Risa Inamura
Secretariat
Kakuhiko Hata
Koji Ono
Makoto Kitazawa
Makoto Ishida
Daigo Kuraishi
Takao Oshimori
Hitoshi Yoshiike
Rieko Komine
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No part of this publication may be reproduced in any manner whatsoever without written
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